Composite plate for an article of footwear

ABSTRACT

A stitched article includes a substrate and a first strand portion formed from a bundle of fibers. The substrate has a first region and a second region. The first strand portion is attached to the substrate in the first region and in the second region via a series of stitches formed with a thread and forms a first layer on the substrate. The article has a first concentration of the stitches in the first region along a first length of the strand portion and a second concentration of the stitches different than the first concentration in the second region along a second length of the first strand portion.

CROSS REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.16/254,975, filed Jan. 23, 2019, which claims priority under 35 U.S.C. §119(e) to U.S. Provisional Application Ser. No. 62/621,193, filed Jan.24, 2018, the disclosures of which are hereby incorporated by referencein their entirety.

FIELD

The present disclosure relates generally to footwear, and in particularthe present disclosure relates to making a composite plate for anarticle of footwear.

BACKGROUND

This section provides background information related to the presentdisclosure which is not necessarily prior art.

Regions of composites that are to accommodate flexing, such as, forexample, in bending regions where toes and joints connect metatarsalbones with phalanx bones of a foot, are more susceptible to crackpropagation and fracturing as a result of repeated bending/flexing ofthe composite during use. Accordingly, in composite articles, fiberdensity is generally reduced in these bending regions in order to reducethe stiffness to allow for bending at the cost of decreasing the overallstrength of the composite article.

DRAWINGS

The drawings described herein are for illustrative purposes only ofselected configurations and not all possible implementations, and arenot intended to limit the scope of the present disclosure.

FIG. 1 is a perspective view of an article of footwear in accordancewith principles of the present disclosure;

FIG. 2 is an exploded view of the article of footwear of FIG. 1 showingan upper and a substantially rigid, three-dimensional footwear plateincluding a composite component affixed to a footbed surface of theupper;

FIG. 3 is a top perspective view of a footwear plate including acomposite component of FIG. 1 showing an inner surface of the footwearplate having a shape that conforms to a surface profile of a bottomsurface of a foot;

FIG. 4 is a top view of a substrate used to form a composite footwearplate for the article of footwear of FIG. 1;

FIGS. 5A and 5B each provide a top view of a strand portion formed frombundle of fibers attached to the substrate of FIG. 4 and forming a firstlayer on the substrate;

FIG. 6A is a close up view of the bundle of fibers of FIG. 5 attached tothe substrate in a heel region via stitching having a firstconcentration;

FIG. 6B is a cross-sectional view taken along line 6B-6B of FIG. 6Ashowing the stitching penetrating the substrate to attach the bundle offibers to a top surface of the substrate and the fibers includingnon-polymer fibers and polymer fibers;

FIG. 7 is a close up view of the bundle of fibers of FIG. 5 attached tothe substrate in a midfoot region via stitching having a secondconcentration that is greater than the first concentration of stitchingin the heel region;

FIG. 8 is a close up view of the bundle of fibers of FIG. 6 attached tothe substrate in a forefoot region via stitching having a thirdconcentration that is greater than the second concentration of stitchingin the midfoot region;

FIG. 9 is a close up view of a bundle of fibers attached to a substratevia stitching having a concentration that increases across a width ofthe substrate in accordance with principles of the present disclosure;

FIG. 10 is a top view of a corresponding layer of a footwear plateformed from a bundle of fibers having distal ends that terminateproximate to a flex zone in a forefoot region of the footwear plate inaccordance with principles of the present disclosure;

FIG. 11 is a top view of a corresponding layer of a footwear plateformed from a bundle of fibers extending along a length of the footwearplate and having a curved orientation proximate to a flex zone in aforefoot region of the footwear plate in accordance with principles ofthe present disclosure;

FIG. 12 top view of a corresponding layer of a footwear plate formedfrom a bundle of fibers extending along a length of the footwear plateand having a curved orientation proximate to a flex zone in a forefootregion of the footwear plate in accordance with principles of thepresent disclosure;

FIGS. 13-15 each show various layers of fiber strands and the bundle offibers of FIG. 11 used to form a corresponding footwear plate inaccordance with principles of the present disclosure;

FIG. 16 is a perspective view of a mold for use in forming a footwearplate in accordance with the principles of the present disclosure, themold shown in conjunction with a stack of fibers prior to being formedinto the footwear plate; and

FIG. 17 is a perspective view of a mold for use in forming a footwearplate in accordance with the principles of the present disclosure, themold shown in conjunction with the formed footwear plate.

Corresponding reference numerals indicate corresponding parts throughoutthe drawings.

DETAILED DESCRIPTION

The present disclosure is directed to a stitched article having one ormore bundles of fibers supported by a substrate. The bundles of fibersmay be attached to the substrate via stitching to secure the bundles tothe substrate at desired locations and/or in a desired pattern. Theconcentration of the stitching used to attach the bundles to thesubstrate may vary at different locations of the substrate to providethe substrate—once formed into a footwear plate, for example—to havedifferent properties. For example, in areas where the plate is expectedto flex and bend, the concentration of the stitching may be increasedrelative to other areas of the substrate in an effort to locallyincrease the flexibility of the formed plate while at the same timeresisting cracking.

One aspect of the disclosure provides a stitched article. The stitchedarticle includes a substrate having a first region and a second region.The stitched article also includes a first strand portion formed from afirst bundle of fibers, attached to the substrate in the first regionand in the second region via a series of stitches formed with a firstthread, and forming a first layer on the substrate. The article has afirst concentration of the stitches in the first region along a firstlength of the strand portion and a second concentration of the stitchesdifferent than the first concentration in the second region along asecond length of the strand portion.

Implementations of the disclosure may include one or more of thefollowing optional features. In some implementations, the stitches crossover the strand portion and penetrate the substrate at first attachmentlocations that are spaced apart from the strand portion. The stitchesmay also penetrate the strand portion. Optionally, the first length mayextend in a direction between a medial side of the substrate and alateral side of the substrate. Here, the second length extends in adirection between the medial side of the substrate and the lateral sideof the substrate.

In some examples, the first concentration is greater than the secondconcentration. The first concentration may be at least 10 percentgreater than the second concentration, may be 10 percent to 50 percentgreater than the second concentration, or may be 20 percent to 40percent greater than the second concentration. Optionally, a firstaverage distance between stitches in the first region may be greaterthan a second average distance between stitches in the second region.Here, the first average distance between stitches may be at least 10percent greater than the second average distance between stitches, maybe 10 percent to 50 percent greater than the second average distancebetween stitches, or may be 20 percent to 40 percent greater than thesecond average distance between stitches

In some configurations, the second concentration is greater than thefirst concentration. The second concentration may be at least 10 percentgreater than the first concentration, 10 percent to 50 percent greaterthan the first concentration, or 20 percent to 40 percent greater thanthe first concentration. Additionally or alternatively, a second averagedistance between stitches in the first region may be greater than afirst average distance between stitches in the second region. Here, thesecond average distance between stitches may be at least 10 percentgreater than the first average distance between stitches, 10 percent to50 percent greater than the first average distance between stitches, or20 percent to 40 percent greater than the first average distance betweenstitches.

In some implementations, the substrate is a textile including fibersand/or yarns formed of a first polymeric composition including one ormore first polymers. The stitching thread may include a second polymericcomposition including one or more second polymers. The substrate may bea textile including a first polymeric composition including one or morefirst polymers where at least one of the one or more first polymers ofthe first polymeric composition of the substrate is the same as at leastone of the one or more second polymers of the second polymericcomposition of the stitching thread. Here, the textile may be anon-woven textile. In some examples, the bundle of fibers includes atleast one of carbon fibers, boron fibers, glass fibers, and syntheticpolymer fibers. The synthetic polymer fibers may be high tenacitysynthetic polymer fibers such as aramid fibers.

In some configurations, the stitched article includes a second strandportion formed from a second bundle of fibers, attached to the substratein the first region and in the second region via a series of stitchesformed with a second thread. The first bundle of fibers may includecarbon fibers. The second bundle of fibers may include glass fibers. Aconcentration of the first bundle of fibers in the first region may beat least 5 weight percent greater than a concentration of the firstbundle of fibers in the second region. Additionally or alternatively, aconcentration of the second bundle of fibers in the second region may beat least 5 weight percent greater than a concentration of the secondbundle of fibers in the first region. Here, a melting temperature of thesecond polymeric composition of the thread may be at least 15 degrees C.higher than a melting temperature of the first polymeric composition ofthe substrate.

In some examples, the series of stitches crosses over the strandportion. Optionally, the second region may define a flex zone having agreater flexibility than the first region. The flexibility of the secondregion may be at least 5 percent greater than the flexibility of thefirst region or may be at least 10 percent greater than the flexibilityof the first region. The second concentration may be greater than thefirst concentration.

In some implementations, the stitched article is a component of anarticle of footwear, an article of apparel, or an article of sportingequipment. The component of the article of footwear may be a componentof a plate of an article of footwear.

Another aspect of the disclosure provides a stitched article. Thestitched article includes a substrate having a first side and a secondside. The stitched article also includes a strand portion formed from abundle of fibers, attached to the substrate via a series of stitchesformed with a thread, forming a first layer on the substrate, andincluding a first length extending in a direction between the first sideand the second side and a second length extending in a direction betweenthe first side and the second side. The stitches have a differentconcentration along the first length than the second length.

Implementation of this aspect may include one or more of the followingoptional features. In some configurations, the stitches cross over thestrand portion and penetrate the substrate at first attachment locationsthat are spaced apart from the strand portion. The stitches may alsopenetrate the strand portion. The substrate may include a first end anda second end, the first length being located closer to the first endthan the second length and having a greater concentration of thestitches than the second length. Here, the substrate may include a flexzone at the first length, the flex zone having a greater flexibilitythan other regions of the substrate.

In some examples, the substrate is a textile including a first polymericcomposition that includes one or more first polymers and the threadincludes a second polymeric composition that includes one or more secondpolymers. In this example, at least one of the one or more firstpolymers is the same type of polymer as at least one of the one or moresecond polymers. Examples of types of polymers suitable for use as thefirst and second polymers of the substrate and the stitching threadinclude polyurethanes, polyethers, polyesters, polyamides, andpolyolefins.

In some configurations, the bundle of fibers includes at least one ofcarbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.The thread forming the stitches may be formed from a polymericcomposition. Optionally, the stitching thread may be formed from apolymeric composition including one or more of the same type(s) ofpolymers as the substrate. Further, a polymeric composition included inthe thread may have a higher melting point than the substrate. Theseries of stitches formed by the stitching thread may also cross overthe strand portion.

Yet another aspect of the disclosure provides a stitched article. Thestitched article includes a substrate having a first side and a secondside. The stitched article includes a strand portion formed from abundle of fibers, attached to the substrate via a series of stitchesformed with a thread, forming a first layer on the substrate, andincluding a first length extending in a direction between the first sideand the second side and a second length extending in a direction betweenthe first side and the second side. A concentration of the stitchesvaries along at least one of the first length and the second lengthbetween the first side and the second side.

This aspect of the disclosure may include one or more of the followingoptional features. In some examples, the stitches cross over the strandportion and penetrate the substrate at first attachment locations thatare spaced apart from the strand portion. The stitches may alsopenetrate the strand portion.

In some implementations, the substrate includes a first end and a secondend, the first length being located closer to the first end than thesecond length and having a greater concentration of the stitches thanthe second length. Here, the substrate may include a flex zone at thefirst length, the flex zone having a greater flexibility than otherregions of the substrate. The substrate may be a textile including afirst polymeric composition including one or more first polymers and thethread may include a second polymeric composition including one or moresecond polymers. Here, at least one of the one or more first polymers isthe same as at least one of the one or more second polymers.

In some configurations, the bundle of fibers includes at least one ofcarbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.The thread forming the stitches may be formed from a polymericcomposition. Optionally, the stitching thread may be formed from apolymeric composition including one or more of the same type(s) ofpolymers as the substrate. Further, a polymeric composition included inthe thread may have a higher melting point than the substrate. Theseries of stitches formed by the stitching thread may also cross overthe strand portion.

Another aspect of the disclosure provides a stitched article. Thestitched article includes a substrate having a first region and a secondregion. The stitched article also includes a strand portion formed froma bundle of fibers, attached to the substrate via a series of stitchesformed with a thread, forming a first layer on the substrate, andincluding a plurality of lengths having longitudinal axes that extend ina direction between the first region and the second region and distalends that terminate at respective locations on the substrate that arespaced apart from an edge of the substrate to define a flex zone of thesubstrate at the distal ends. The flex zone has a greater flexibilitythan other regions of the substrate.

Implementations of this aspect of the disclosure may include one or moreof the following optional features. In some implementations, the distalends cooperate to form a transition line that extends across a width ofthe substrate between a first side of the substrate and a second side ofthe substrate. Here, the transition line is arcuate or the transitionline is straight. Optionally, the transition line may extend from thefirst side to the second side. Additionally or alternatively, thesubstrate may be exposed between the transition line and the edge.

In some configurations, the substrate is exposed between the distal endsand the edge. The stitches may cross over the strand portion andpenetrate the substrate at first attachment locations that are spacedapart from the strand portion. The stitches may also penetrate thestrand portion.

In some examples, a concentration of the stitches is different along atleast one of the plurality of lengths than the other of the plurality oflengths. In this example, a concentration of the stitches varies along alength of at least one of the lengths of the plurality of lengths. Inother examples, a concentration of the stitches varies along a length ofat least one of the lengths of the plurality of lengths.

In some implementations, the substrate is a textile including a firstpolymeric composition comprising one or more first polymers and thethread includes a second polymeric composition comprising one or moresecond polymers. Here, at least one of the one or more first polymers isthe same as at least one of the one or more second polymers.

In some configurations, the bundle of fibers includes at least one ofcarbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.The thread forming the stitches may be formed from a polymericcomposition. Optionally, the stitching thread may be formed from apolymeric composition including one or more of the same type(s) ofpolymers as the substrate. Further, a polymeric composition included inthe thread may have a higher melting point than the substrate. Theseries of stitches formed by the stitching thread may also cross overthe strand portion.

An additional aspect of the disclosure provides a stitched article. Thestitched article includes a substrate having a first region and a secondregion. The stitched article further includes a strand portion formedfrom a bundle of fibers, attached to the substrate via a series ofstitches formed with a thread, forming a first layer on the substrate,and including a flex zone having a greater flexibility than otherregions of the substrate. The stitches have a greater concentrationalong a length of the strand portion within the flex zone than in theother regions of the substrate.

Aspects of this disclosure may include one or more of the followingoptional features. In some configurations, the flex zone defines atransition line that extends across a width of the substrate between afirst side of the substrate and a second side of the substrate. Thetransition line may be arcuate or the transition line may be straight.Further, the transition line may extend from the first side to thesecond side. Optionally, the substrate may be exposed between thetransition line and an edge of the substrate.

In some examples, the stitches cross over the strand portion andpenetrate the substrate at first attachment locations that are spacedapart from the strand portion. Additionally or alternatively, thestitches may penetrate the strand portion. Further, the substrate may bea textile including a first polymeric composition including one or morefirst polymers and the thread may include a second polymeric compositionincluding one or more second polymers. At least one of the one or morefirst polymers may be the same as at least one of the one or more secondpolymers.

In some configurations, the bundle of fibers includes at least one ofcarbon fibers, boron fibers, glass fibers, and synthetic polymer fibers.The thread forming the stitches may be formed from a polymericcomposition. Optionally, the stitching thread may be formed from apolymeric composition including one or more of the same type(s) ofpolymers as the substrate. Further, a polymeric composition included inthe thread may have a higher melting point than the substrate. Theseries of stitches formed by the stitching thread may also cross overthe strand portion.

Another aspect of the disclosure provides a method for forming astitched article. The method includes positioning a substrate anddepositing a strand portion formed from a bundle of fibers on asubstrate. The method also includes attaching the strand portion to thesubstrate via a series of stitches formed with a thread such that afirst region of the stitched article has a first concentration ofstitches and a second region of the stitched article has a secondconcentration of stitches, wherein the first concentration of stitchesis at least 10 percent greater than the second concentration ofstitches. Optionally the stitched article may be a stitched articleaccording to any of the systems or methods disclosed herein.

Another aspect of the disclosure provides a method of forming acomposite article. The method includes positioning a stitched article ina mold, the stitched article including strand portions of bundles offibers stitched to a substrate with a thread. While the stitched articleis positioned in the mold, the method further includes consolidating thesubstrate, the strand portion, and the stitches via a resin compositionto form a composite article. The method also includes removing thecomposite article from the mold. The composite article includes a firstregion and a second region. The second region includes a flex zonehaving a greater flexibility than the first region.

Implementations of the disclosure may include one or more of thefollowing optional features. In some implementations, the methodincludes forming the stitched article prior to positioning the stitchedarticle in the mold. Forming the stitched article may include depositinga strand portion formed from a bundle of fibers on a substrate andattaching the strand portion via a series of stitches formed with athread to the substrate in a first region having a first concentrationof stitches and in a second region having a second region of stitchesgreater than the first concentration of stitches.

In some examples, consolidating the substrate, the strand portion, andthe stitching includes applying the resin composition to the substrate,the strand portion, and the stitching while the stitched article ispositioned in the mold. Applying the resin composition may includecombining first and second reactive compositions to form a liquid resincomposition, and applying the liquid resin composition to the stitchedarticle. The liquid resin composition may be a liquid epoxy resincomposition.

In some configurations, the method includes curing the resin compositionprior to removing the composite article from the mold. Optionally, theresin composition may be a thermoplastic resin composition containedwithin at least one of the substrate, the strand portion, and the threadof the stitched article. Consolidating the substrate, the strandportion, and the thread may include causing the resin composition toflow and infiltrate the fibers of the strand portion, followed byallowing the resin composition to re-solidify prior to removing thecomposite article from the mold. The method may further include trimminga perimeter of the composite article.

In some implementations, the composite article is a component for anarticle of footwear, apparel, or sporting equipment. When the compositearticle is a component for an article of footwear, the method furtherincludes incorporating the component for an article of footwear into anarticle of footwear.

In some configurations, depositing the strand portion on the substrateincludes positioning the strand portion in a plurality of lengths havinglongitudinal axes that extend in a direction between the first regionand the second region. The plurality of lengths may have distal endsthat terminate at respective locations on the substrate that are spacedapart from an edge of the substrate to define the flex zone. Optionally,depositing the strand portion on the substrate may include positioningthe strand portion in a plurality of lengths having a firstsubstantially straight portion within the first region and an arcuateportion within the second region that defines the flex zone. Here, themethod may include aligning arcuate portions of adjacent lengths todefine the flex zone.

In some examples, attaching the strand portion via a series of stitchesformed with a thread includes causing the stitches to cross over thestrand portion and penetrate the substrate at first attachment locationsthat are spaced apart from the strand portion. Additionally oralternatively, attaching the strand portion via a series of stitchesformed with a thread includes causing the stitches to penetrate thestrand portion.

Yet another aspect of the disclosure provides a method of manufacturingan article of footwear, apparel or sporting equipment. The methodincludes positioning a composite article. The composite article includesa stitched article having strand portions of bundles of fibers stitchedto a substrate with a thread. The fibers are consolidated by a resincomposition. The composite article is a component of an article offootwear, apparel, or sporting equipment. The method also includesaffixing the composite article and a second component to each other. Thesecond component is a second component of an article of footwear,apparel, or sporting equipment.

Implementations of this aspect of the disclosure may include one or moreof the following optional features. In some implementations, thecomposite article is a component of an article of footwear, and thesecond component is a second component of an article of footwear.Optionally, the composite article may be a plate for an article offootwear.

Further areas of applicability will become apparent from the descriptionprovided herein. The description and specific examples in this summaryare intended for purposes of illustration only and are not intended tolimit the scope of the present disclosure.

Example configurations will now be described more fully with referenceto the accompanying drawings. Example configurations are provided sothat this disclosure will be thorough, and will fully convey the scopeof the disclosure to those of ordinary skill in the art. Specificdetails are set forth such as examples of specific components, devices,and methods, to provide a thorough understanding of configurations ofthe present disclosure. It will be apparent to those of ordinary skillin the art that specific details need not be employed, that exampleconfigurations may be embodied in many different forms, and that thespecific details and the example configurations should not be construedto limit the scope of the disclosure.

The terminology used herein is for the purpose of describing particularexemplary configurations only and is not intended to be limiting. Asused herein, the singular articles “a,” “an,” and “the” may be intendedto include the plural forms as well, unless the context clearlyindicates otherwise. The terms “comprises,” “comprising,” “including,”and “having,” are inclusive and therefore specify the presence offeatures, steps, operations, elements, and/or components, but do notpreclude the presence or addition of one or more other features, steps,operations, elements, components, and/or groups thereof. The methodsteps, processes, and operations described herein are not to beconstrued as necessarily requiring their performance in the particularorder discussed or illustrated, unless specifically identified as anorder of performance. Additional or alternative steps may be employed.

When an element or layer is referred to as being “on,” “engaged to,”“connected to,” “attached to,” or “coupled to” another element or layer,it may be directly on, engaged, connected, attached, or coupled to theother element or layer, or intervening elements or layers may bepresent. In contrast, when an element is referred to as being “directlyon,” “directly engaged to,” “directly connected to,” “directly attachedto,” or “directly coupled to” another element or layer, there may be nointervening elements or layers present. Other words used to describe therelationship between elements should be interpreted in a like fashion(e.g., “between” versus “directly between,” “adjacent” versus “directlyadjacent,” etc.). As used herein, the term “and/or” includes any and allcombinations of one or more of the associated listed items.

The terms first, second, third, etc. may be used herein to describevarious elements, components, regions, layers and/or sections. Theseelements, components, regions, layers and/or sections should not belimited by these terms. These terms may be only used to distinguish oneelement, component, region, layer or section from another region, layeror section. Terms such as “first,” “second,” and other numerical termsdo not imply a sequence or order unless clearly indicated by thecontext. Thus, a first element, component, region, layer or sectiondiscussed below could be termed a second element, component, region,layer or section without departing from the teachings of the exampleconfigurations.

Referring to FIGS. 1-9, in some implementations, an article of footwear10 includes an upper 100 and a footwear plate 200 attached to the upper100. FIG. 1 provides a front perspective view of the footwear 10 dividedinto one or more portions. The portions may include a forefoot portion12, a mid-foot portion 14, and a heel portion 16. The forefoot,mid-foot, and heel portions 12, 14, 16 may alternatively be referred toas forefoot, mid-foot, and heel regions 12, 14, 16, respectively. Theforefoot portion 12 may correspond with toes and joints connectingmetatarsal bones with phalanx bones of a foot. The mid-foot portion 14may correspond with an arch area of the foot, and the heel portion 16may correspond with rear portions of the foot, including a calcaneusbone. The footwear 10 may include lateral and medial sides 18, 20,respectively, corresponding with opposite sides of the footwear 10 andextending through the portions 12, 14, 16.

The upper 100 includes interior surfaces that define an interior void102 configured to receive and secure a foot for support on the solestructure 200. Ankle opening 104 located in the heel portion 16 mayprovide access to the interior void 102. For example, the ankle opening104 may receive a foot to secure the foot within the void 102 andfacilitate entry and removal of the foot to and from the interior void102. In some examples, one or more fasteners 106 extend along the upper100 to adjust a fit of the interior void 102 around the foot whileconcurrently accommodating entry and removal of the foot therefrom. Theupper 100 may include apertures such as eyelets and/or other engagementfeatures such as fabric or mesh loops that receive the fasteners 106.The fasteners 106 may include laces, straps, cords, hook-and-loop, orany other suitable type of fastener.

The upper 100 may include a tongue portion 110 that extends between theinterior void 102 and the fasteners 106. The upper 100 may be formedfrom one or more materials that are stitched or adhesively bondedtogether to form the interior void 102. Suitable materials of the uppermay include, but are not limited, textiles, foam, leather, and syntheticleather. The materials may be selected and located to impart propertiesof durability, air-permeability, wear-resistance, flexibility, andcomfort.

Referring to FIG. 2, an exploded view of the article of footwear 10 ofFIG. 1 shows a footbed surface 222 disposed between the plate 200 andthe upper 100 for receiving a bottom surface (e.g., plantar) of the footwithin the interior void 102. The footbed surface 222 may be integrallyformed with the upper 100 in some configurations, or the footbed surface222 may correspond to a separately formed layer that attaches to theupper 100 in other configurations. In some examples, the footbed surface222 is contoured to conform to a profile of the plantar of the foot.Additionally or alternatively, an insole or sockliner may be disposedupon the footbed surface 222 under the foot within at least a portion ofthe interior void 102 of the upper 100 to enhance comfort of thefootwear 10.

The footwear plate 200 defines a longitudinal axis L that extendsthrough the forefoot portion 12, the mid-foot portion 14, and the heelportion 16. The plate 200 attaches to the upper 100 and may impartfeatures that a conventional outsole provides. FIG. 3 provides a topperspective view of the embroidered plate 200 showing the plate 200having a ground-engaging surface 212 and an opposite inner surface 214that opposes the footbed surface 222. In some examples, an outsolematerial, such as rubber, is attached to the ground-engaging surface 212to provide traction with the ground surface. The inner surface 214 maybe contoured to the shape of the footbed surface 222 to conform to theprofile of the bottom surface (e.g., plantar) of the foot within theinterior void 102. In some examples, a sidewall 220 extends around aperimeter of the plate 200 between the ground-engaging surface 212 andthe inner surface 214. The sidewall 220 and the inner surface 214 of theplate 200 may cooperate to retain and support the foot upon the plate200 when the interior void 102 receives the foot therein. For instance,the sidewall 220 may define a rim around the perimeter of the contouredinner surface 214 to cradle the foot during use of the footwear 10 whenperforming walking, running, and/or lateral movements. In someimplementations, portions of the sidewall 220 extend around the upper100 and attach to exterior surfaces of the upper 100 at one or morelocations to secure the plate 200 to the upper 100. Adhesives may beused to secure the plate 200 to the upper 100.

In some examples, one or more protruding elements 215 (e.g., cleats)extend from the ground-engaging surface 212 in a direction away from theplate 200 and the upper 100 to provide traction with soft groundsurfaces, such as grass. For instance, a cleat shaft 217 associated witheach protruding element 215 may attach to the ground-engaging surface212 of the plate 200 and extend in a direction substantiallyperpendicular to the longitudinal axis L of the plate 200.

In some implementations, the footwear plate 200 is substantially rigidand formed from one or more composite materials. By contrast toconventional composite plates formed from unidirectional tapes that onlyafford directional stiffness properties, the footwear plate 200 isformed from one or more strand portions 300 arranged in selectedpatterns to impart anisotropic stiffness and gradient load pathsthroughout the plate 200. Each strand portion 300 may refer to a bundleof a plurality of fibers 350, a monofilament, yarn, or polymerpre-impregnated bundles that include ribbon or strips of unidirectionaltape. The present disclosure will refer to each strand portion 300 as acorresponding bundle 300 of fibers 350 unless indicated otherwise. Asused herein, the term “bundle” refers to a bundle (i.e., plurality) offilaments (e.g., fibers 350) that may be twisted or untwisted and eachbundle may be designated a size associated with a number of fibers 350the corresponding bundle 300 contains. For instance, the at least onebundle 300 forming the footwear plate 200 may range in size from about1,000 fibers per bundle to about 48,000 fibers per bundle.

In some configurations, the fibers 350 associated with the at least onebundle 300 include at least one of carbon fibers, glass fibers, boronfibers, and/or synthetic polymer fibers. Synthetic polymer fibers mayinclude high tenacity synthetic polymer fibers such as aramid fibers.Additionally, at least a portion of the fibers 350 associated with theat least one bundle 300 may be formed from a first thermoplasticmaterial. Fibers such as carbon fibers, aramid fibers, and boron fibersmay provide a high modulus while glass fibers (e.g., fiberglass) andpolymer fibers (e.g., nylon or polyester fibers) provide a mediummodulus. Additionally or alternatively, fibers or yarns formed of athermoplastic composition, may be comingled with the fibers 350 of theone or more bundles 300 to assist with melting/infusing the embroideredpreform during vacuum molding or compression molding.

In some implementations, a resin composition is used to consolidate thefibers of the strands, forming a composite article. In some examples, inaddition to consolidating the fibers to the strands, the resincomposition also consolidates the fibers of the substrate, or the fibersof the stitching thread, or the fibers of both the substrate and thestitching thread in the composite article. The resin composition can beapplied to the stitched article as a liquid which infiltrates into andaround the fibers of the stitched article. The liquid resin compositionis then solidified while in contact with the fibers and thusconsolidates the fibers in the solid resin composition in the compositearticle. In one example, the liquid resin composition solidifies into athermoset resin composition, and the composite article comprises fibersconsolidated by the thermoset resin composition. The thermoset resincomposition may be formed by combining first and second reactivecompositions. Alternatively or additionally, the thermoset resincomposition may be formed by exposing the liquid resin composition toactinic radiation (e.g., by exposure to light or heat or both). Theliquid resin composition may include one or more epoxy polymer, or oneor more precursor to an epoxy polymer. In another example, the liquidresin composition solidifies into a thermoplastic resin composition, andthe composite article comprises fibers consolidated by the thermoplasticresin composition. The thermoplastic resin composition may include oneor more thermoplastic polyurethane, one or more thermoplastic polyester,one or more thermoplastic polyether, one or more thermoplasticpolyamide, one or more thermoplastic polyolefin, or any combinationthereof.

In some examples, the density of fiber per unit area varies within asingle bundle 300 of fibers 350. Additionally or alternatively, the typeof fibers 350 forming a corresponding bundle 300 may vary across theplate 200 between the forefoot region 12 and the heel region 16 andbetween the lateral side 18 and the medial side 20. In doing so, theplate 200 can be designed to have a stiffness gradient based onanatomical features of the foot so that the plate 200 flexes in a waythat matches the natural flex of the foot during walking, running, orother athletic movements. For instance, a stiffness of the plate 200 mayincrease along the length of the plate 200 from the forefoot portion 12to the heel portion 14 and/or a stiffness of the plate 200 may bereduced to define a flex zone, such as where toes and joints connectmetatarsal bones with phalanx bones of a foot, to allow the plate 200 tobend/flex while mitigating crack propagation at the flex zone. In someexamples, the patterns for each bundle 300 of fibers 350 provides astiffness gradient between the lateral side 18 and the medial side 20 ofthe plate 200 through at least one of the portions 12, 14, 16. Thus, theone or more bundles 300 of fibers 350 may include paths with multiplecurves to change directions in the load path of the plate 200 toaccommodate anatomical features as well as to enhance performance of thefootwear 10 for its intended use. Moreover, to increase inter-laminarfracture toughness at localized regions of the plate 200 such as flexzones, a concentration of stitching 304 (FIGS. 6-9) used to attach thebundles 300 of fibers 350 to a substrate 400 (FIG. 4) can be higherwithin the flex zones of the plate 200 and/or additional embroiderystitching may be laid over top of already stitched down bundles 300 offibers 350 proximate to the flex zones. Here, a spacing of the stitchingand/or embroidery stitching may be decreased within the flex zones ofthe plate 200 so that the stitching density (i.e., concentration) isincreased to thereby increase the inter-laminar facture toughness in theflex zone where flexing/bending of the plate 200 occurs repeatedlyduring use of the plate 200. In some implementations, the plate 200 isformed by embroidering at least two bundles 300 of fibers 350 in alayered configuration while being affixed via stitching to a samesubstrate 400 (FIGS. 13-15). In other implementations, the plate isformed by affixing at least two bundles 300 of fibers 350 separately tocorresponding substrates and stacking the substrates such that the atleast two bundles 300 of fibers 350 are embroidered in a layeredconfiguration.

As used herein, the substrate 400 refers to any one of a veil, carrier,or backer at which the at least one bundle 300 of fibers 350 affixes toand binds with. The substrate 400 may be formed from a thermosetpolymeric material or a thermoplastic polymeric material and can be atextile (e.g., knit, woven, or non-woven), an injection molded article,or a thermoformed article. The polymeric material of the substrate caninclude one or more polyurethane, one or more polyether, one or morepolyester, one or more polyamide, one or more polyolefin, andcombinations thereof. For example, the polyurethane can be apolyester-polyurethane copolymer. The polyester can be a polyethyleneterepthalate or a polybutylene terephtalate. The polyamide can be Nylon6, Nylon 66, or Nylon 11.

The stitching 304 used to attach bundles 300 of fibers 350 to thesubstrate 400 may be formed from the same material as the substrate 400.For instance, the stitching 304 may include a thread formed from apolymeric composition that includes some of the same polymers as thepolymeric composition of the substrate 400. The polymeric material ofthe stitching can include one or more polyurethane, one or morepolyether, one or more polyester, one or more polyamide, one or morepolyolefin, and combinations thereof. For example, the polyurethane canbe a polyester-polyurethane copolymer. The polyester can be apolyethylene terepthalate or a polybutylene terephtalate. The polyamidecan be Nylon 6, Nylon 66, or Nylon 11.

In some examples, the substrate 400 (e.g., a textile) may comprise afirst polymeric composition having one or more first polymers, and thethread of the stitching may comprise a second polymeric compositionhaving one or more second polymers with at least one of the one or moresecond polymers being the same type of polymer as at least one of theone or more first polymers. For example, both the first polymericcomposition and the second polymeric may comprise a polyurethane, orboth the first polymeric composition and the second polymeric maycomprise a polyester, or both the first polymeric composition and thesecond polymeric may comprise a polyamide, etc. Additionally oralternatively, the thread of the stitching may include a secondpolymeric composition having a higher melting temperature than the firstpolymeric composition of the substrate. More specifically, athermoplastic composition present in or forming a majority of the weightof the thread of the stitching may have a melting temperature which isat least 20-degrees Celsius higher than the melting temperature of apolymeric composition present in the substrate 400. For instance, thethread of the stitching may include a polymeric composition having amelting temperature that is at least 20-degrees Celsius higher than afirst polymeric composition included in the substrate 400, or of a firstpolymeric composition which forms a majority of the weight of thesubstrate 400.

Generally, it is difficult to manufacture a non-flat (e.g.,curved/contoured) and substantially rigid composite plate in its finalstate from a preform plate that is initially rigid and flat in shape.Implementations herein are directed toward an embroidered preform thataffixes the one or more bundles 300 of fibers 350 to the same substrate400 or different substrates 400, reducing a concentration of the bundles300 of fibers 350 and/or curving paths of the bundles of fibers 350 inlocalized areas associated with flex zones, increasing aconcentration/density of stitching used to affix the bundles of fibers350 to the substrate(s) 400 in the localized areas to increaseinter-laminar fracture toughness, and applying heat to mold theembroidered preform to form the footwear plate 200 with a desired shapeand curvature. Thereafter, the plate 200 may be cured to impartstructural rigidity. That is to say, both the substrate(s) 400 and eachbundle 300 of fibers 350 are thin and flexible to allow the embroideredpreform to be positioned into a mold to form the plate 200 with athree-dimensional shape having structural rigidity. In some examples,manufacturing the plate 200 includes infusing liquid thermoplasticmaterial into the embroidered preform (e.g., one or more bundles 300 offibers 350 affixed to the substrate 400) and using vacuum molding and/orcompression molding techniques to form the plate 200. The liquidthermoplastic material may include at least one of polymerizablecompositions or pre-polymer materials. Additional polymers/tougheningagents (such as softer polymers, rubber, and/or block copolymers) may beadded to the liquid thermoplastic material to reduce brittleness of theplate 200.

In other examples, the substrate 400, or a portion thereof, is formedfrom a thermoset polymeric material and/or a thermoplastic polymericmaterial. The thermoplastic polymeric material includes a melting pointbelow a melting point or degradation temperature of the fibers 350 ofthe bundles 300. Here, incorporating the thermoplastic material and/orthe thermoset polymeric material into the substrate 400 may be used inaddition to, or in lieu of, the liquid thermoplastic material infusedinto the embroidered preform to melt/infuse the embroidered preformduring the vacuum molding process and/or the compression moldingprocess.

Additionally or alternatively, thermoplastic yarns may be comingled withthe fibers 350 of the one or more bundles 300 to assist withmelting/infusing the embroidered preform during vacuum molding orcompression molding. Optionally, the embroidered preform may be powdercoated with the thermoset and/or thermoplastic polymeric materials orinjection-molding techniques may be used to overmold and/or impregnatethe embroidered preform with the thermoset and/or thermoplasticpolymeric materials.

FIG. 4 provides a top view of an example substrate 400 used for formingthe footwear plate 200. The substrate 400 may be substantially thin,flat, and flexible. As set forth above, the substrate 400, or at least aportion thereof, may be formed from a thermoset polymeric material or athermoplastic polymeric material. In some configurations, the substrate400 includes a textile that may be knit, woven, or non-woven. Thesubstrate 400 may also optionally be formed form an injection moldedarticle or a thermoformed article. The substrate 400 may be cut to adesired shape defined by a perimeter edge 402.

FIGS. 5A and 5B each provide a top view of a bundle 300 of fibers 350attached to a top surface 410 of the substrate 400 of FIG. 4 to form afirst layer on the substrate 400. The bundle 300 (i.e., strand portion)includes a plurality of segments 302 that extend continuously betweentwo different locations along the perimeter edge 402 of the substrate400 to form the first layer covering the substrate 400 (i.e., thesegments 302 extend across the substrate 400 between the lateral andmedial sides 18, 20). The segments 302 may be disposed adjacent andsubstantially parallel to one another. In the examples shown, thesegments 302 extend in a direction that converges with the longitudinalaxis of the substrate 400. In other examples, the segments 302 mayextend substantially parallel with the longitudinal axis of thesubstrate 400 or extend in other directions convergent with thelongitudinal axis of the substrate 400. FIG. 5A shows each segmentterminating at a corresponding looped portion inside the perimeter edge402 of the substrate 400. FIG. 5B shows each segment also terminating ata corresponding looped portion, but outside the perimeter edge 402 ofthe substrate 400. Thus, the looped portions of the segments 302 of FIG.5B that extend outside the perimeter edge 402 of the substrate 400 maybe removed (e.g., by cutting) to eliminate a presence of pinch pointsduring the manufacturing process when the bundle 300 and fibers 300 andthe substrate 400 are subjected to heat and pressure.

The bundle of fibers 350 may be attached to the substrate 400 via aseries of stitches 304. Referring to FIGS. 6A-8, close-up views in theheel region 16 (FIG. 6A), the midfoot region 14 (FIG. 7), and theforefoot region 12 (FIG. 8) each show a corresponding length/portion ofthe bundle 300 of fibers 350 attached to the substrate 400 via stitching304. The bundle 300 is disposed upon the top surface 410 of thesubstrate 400 and the stitching 304 crosses (e.g., zigzags) over thebundle 300 and penetrates the substrate 400 at attachment locations 305that are spaced apart from the bundle 300. Additionally oralternatively, portions of the stitching 304 may extend through thebundle 300 of fibers 350. The substrate 400 and the stitching 304 may beformed from thermoplastic polymer materials that melt during thermalprocessing. The stitching 304 may be formed from a first thermoplasticpolymer material and the substrate 400 may be formed from a secondthermoplastic polymer material having a lower melting temperature thanthe first thermoplastic polymer material. Thus, the stitching 304 mayretain the bundle 300 of fibers 350 in place without melting when thesubstrate 400 begins to melt during the thermal processing. In someexamples, the stitching 304, or at least a portion thereof, is formedfrom resin. The stitching 304 may also include materials that matchoptional infused polymers used for compression molding and/or vacuummolding. The fibers 350 associated with the bundle 300 may includenon-polymer fibers 352 and polymer fibers 354. For instance, thenon-polymer fibers 352 may include carbon fibers, glass fibers, and/orboron fibers. Synthetic polymer fibers may include high tenacitysynthetic polymer fibers such as aramid fibers. The polymer fibers 354,on the other hand, may include thermoplastic polymer fibers having ahigher melting temperature than that of the thermoplastic polymermaterials used to form the substrate 400 and/or the stitching 304.Moreover, the thermoplastic polymer materials used to form the substrate400 may include a melting temperature that is below a degradationtemperature associated with the non-polymer fibers 352 (e.g., carbonfibers).

The concentration of the stitching 304 may be greater in some localizedregions of the plate 200 (or other stitched article) for increasinginter-laminar fracture toughness, while other regions not in need ofincreased fracture toughness can include a lower concentration ofstitching 304 that is suitable for attaching the bundle 300 of fibers350 to the substrate 400. Moreover, the regions associated with thelower concentration of stitching 304 decrease manufacturing times whenattaching the bundle 300 of fibers 350 to the substrate 400. In someexamples, the localized regions benefitting from an increased fracturetoughness include flex zones where flexing/bending of the formed plate200 (or other article) occurs repeatedly during use of the plate 200. Insome examples, the midfoot region 14 includes a higher concentration ofstitching 304 than the heel region 16 and the forefoot region 12includes a higher concentration of stitching 304 than the midfoot region14. In some implementations, higher concentrations of stitching 304 maybe provided by applying the stitching 304 to the substrate 400 asembroidery without crossing over the bundle 300 such that the density ofstitching 304 is increased to increase the inter-laminar fracturetoughness in localized regions.

Referring to FIG. 6A, the bundle 300 of fibers 350 is attached to thesubstrate 400 in the heel region 16 via a first series of stitches 304formed with the thread and having a first concentration along a firstlength of the bundle 300 of fibers 350. The first length of the bundle300 may correspond to one of the segments 302 in the heel region 16extending in a direction (i.e., convergent to the longitudinal axis L ofthe substrate 400) between the lateral side 18 of the substrate 400 andthe medial side 20 of the substrate 400. In the example shown, the firstconcentration/density of the stitches 304 is proportional to a firstlength L₁ separating adjacent attachment locations 305 disposed on asame side of the bundle 300. For instance, the stitching 304 may crossover the bundle 300 from a first attachment location 305-1 on one sideof the bundle 300 to a second attachment 305-2 on the other side of thebundle, and then back again to the other side of the bundle 300 bycrossing over the bundle 300 from the second attachment location 305-2to a third attachment location 305-3. Here, the first length L₁separates the adjacent first and third attachment locations 305-1 and305-3 disposed on the same side of the bundle 300.

FIG. 6B provides a cross-sectional view taken along line 6B-6B of FIG.6A showing the stitching 304 attaching the bundle 300 of fibers 350 tothe top surface 410 of the substrate 400. The stitching 304 maypenetrate through the surfaces 410, 412 of the substrate 400 and zigzagacross the bundle 300 between the first attachment locations 305. Thenon-polymer fibers 352 (e.g., carbon fibers) and the polymer fibers 354(e.g., thermoplastic polymer fibers) may include circular cross sectionsthat co-mingle with each other throughout the length of the bundle 300.

Referring to FIG. 7, the bundle 300 of fibers 350 is attached to thesubstrate 400 in the midfoot region 14 via a second series of stitches304 formed with the thread and having a second concentration along asecond length of the bundle 300 of fibers 350. Here, the secondconcentration/density of stitches 304 along the second length of thebundle 300 in the midfoot region 14 is greater than the firstconcentration/density of stitches 304 along the first length of thebundle 300 in the heel region 16 of FIG. 6A. The thread forming thefirst and second series of stitches 304 may be continuous ordiscontinuous. The second length of the bundle 300 may correspond to oneof the segments 302 in the midfoot region 14 extending in a direction(i.e., convergent to the longitudinal axis L of the substrate 400)between the lateral side 18 of the substrate 400 and the medial side 20of the substrate 400. As with the first concentration/density ofstitching 304 in the heel region 16 along the first length, the secondconcentration/density of stitching 304 in the midfoot region 14 alongthe second length of the bundle 300 may be proportional to a secondlength L₂ separating adjacent attachment locations 305 disposed on asame side of the bundle 300. In the example shown, the second length L₂separating the adjacent attachment locations 305 associated with thesecond length of the bundle 300 is shorter than the first length L₁separating the adjacent attachment locations 305 associated with thefirst length of the bundle 300. Accordingly, the stitched article (e.g.,bundle 300 and substrate 400) includes a higher concentration/density ofstitches 304 in the midfoot region 14 along the second length of thebundle 300 than in the heel region 16 along the first length of thebundle 300.

In some implementations, the second concentration is at least 10-percent(10%) greater than the first concentration. In some examples, the secondconcentration is 10-percent (10%) to 50-percent (50%) greater than thefirst concentration. The second concentration may be 20-percent (20%) to40-percent (40%) greater than the first concentration. While theexamples show the second concentration of stitches 304 in the midfootregion 14 being greater than the first concentration of stitches 304 inthe heel region 16, the first concentration of stitches in the heelregion 16 may be greater than the second concentration of stitches 304in the midfoot region 14 in other examples.

The stitching 304 in the heel region 16 along the first length of thebundle 300 may include a first average distance between adjacentstitches and the stitching 304 in the midfoot region 14 along the secondlength of the bundle 300 may include a second average distance betweenadjacent stitches. In some examples, the second average distance betweenstitches in the midfoot region 14 is greater than the first averagedistance between stitches in the heel region 16. For instance, thesecond average distance between stitches 304 may be at least 10-percent(10%) greater than the first average distance. In some configurations,the second average distance is 10-percent (10%) to 50-percent (50%)greater than the first average distance. In other configurations, thesecond average distance is 20-percent (20%) to 40-percent (40%) greaterthan the first average distance.

Referring to FIG. 8, the bundle 300 of fibers 350 is attached to thesubstrate 400 in the forefoot region 12 via a third series of stitches304 formed with the thread and having a third concentration along athird length of the bundle 300 of fibers 350. Here, the thirdconcentration/density of stitches 304 along the third length of thebundle 300 in the forefoot region 12 is greater than the secondconcentration/density of stitches 304 along the second length of thebundle 300 in the midfoot region 14 of FIG. 7 (and also the firstconcentration/density of stitches 304 along the first length of thebundle 300 in the heel region 16 of FIG. 6A). The thread forming thethird series of stitches 304 may be continuous or discontinuous with thethreads forming the first and/or the second series of stitches 304. Thethird length of the bundle 300 may correspond to one of the segments 302in the forefoot region 12 extending in a direction (i.e., convergent tothe longitudinal axis L of the substrate 400) between the lateral side18 of the substrate 400 and the medial side 20 of the substrate 400. Inthe example shown, the third concentration/density of stitching 304 inthe forefoot region 12 along the third length of the bundle 300 isproportional to a third length L₃ separating adjacent attachmentlocations 305 disposed on a same side of the bundle 300. Here, the thirdlength L₃ separating the adjacent attachment locations 305 associatedwith the third length of the bundle 300 is shorter than both the secondlength L₂ separating the adjacent attachment locations 305 of FIG. 7 andthe first length L₁ separating the adjacent attachment locations of FIG.6A. Accordingly, the stitched article (e.g., bundle 300 and substrate400) includes a higher concentration/density of stitches in the forefootregion 12 along the third length of the bundle 300 than in both themidfoot region 14 along the second length of the bundle 300 and in theheel region 16 along the first length of the bundle 300. Theconcentration/density of stitching 304 may also be increased byincorporating embroidery stitching that secures and penetrates thesubstrate 400 but does not cross over, or otherwise function, toattach/secure the bundle 300 of fibers 350 to the substrate 400. The useof embroidery stitching merely increases the concentration/density ofstitching 304 in localized regions where increasing the inter-laminarfracture toughness is desirable, such as along flex zones of thefinished article (e.g., the footwear plate 200).

In some implementations, the third concentration is at least 10-percent(10%) greater than the second concentration. In some examples, the thirdconcentration is 10-percent (10%) to 50-percent (50%) greater than thesecond concentration. The third concentration may be 20-percent (20%) to40-percent (40%) greater than the second concentration. While theexamples show the third concentration of stitches 304 in the forefootregion 12 being greater than the second concentration of stitches 304 inthe midfoot region 14, the second concentration of stitches in themidfoot region 14 may be greater than the third concentration ofstitches 304 in the forefoot region 12 in other examples.

The stitching 304 in the midfoot region 14 along the second length ofthe bundle 300 may include the second average distance between adjacentstitches and the stitching 304 in the forefoot region 12 along the thirdlength of the bundle 300 may include a third average distance betweenadjacent stitches. In some examples, the third average distance betweenstitches in the forefoot region 12 is greater than the second averagedistance between stitches in the midfoot region 14. For instance, thethird average distance between stitches 304 may be at least 10-percent(10%) greater than the second average distance. In some configurations,the third average distance is 10-percent (10%) to 50-percent (50%)greater than the second average distance. In other configurations, thethird average distance is 20-percent (20%) to 40-percent (40%) greaterthan the second average distance.

While the examples of FIGS. 6A-8 describe the concentration/density ofstitching 304 across lengths of the bundle 300 increasing from the heelregion 16 to the forefoot region 12, other examples can include theconcentration/density of the stitching 304 across lengths of the bundle300 increasing from the forefoot region 12 to the heel region 16 withoutdeparting from the scope of the present disclosure. Moreover, theconcentration/density of stitching 304 across length(s) of one or morebundles 300 in the midfoot region 14 may be higher or lower than theconcentration/density of stitching 304 in the forefoot and heel region12 and 16. Accordingly, any length/portion/segment of the bundle 300extending along the substrate 400 can be selected to incorporate anyconcentration/density of stitching 304 to achieve desirable strength andtoughness properties in localized regions of the finished article (e.g.,plate 200). For example, a higher concentration/density of stitching 304may be utilized in localized areas associated with flex zones of afootwear plate 200 to mitigate crack propagation due to repeatedbending/flexing. Additionally, while the attachment locations 305 areshown as being spaced apart from the bundle 300 such that the stitching304 crosses over the bundle 300, other examples may include thestitching 304 penetrating through the bundle 300 along the length at oneor more locations,

In some implementations, a stitched article (i.e., the bundle 300 andsubstrate 400) includes a concentration of stitches 304 that variesalong a length of the bundle of the fibers in a localized region.Referring to FIG. 9, a close-up view shows a correspondinglength/portion of the bundle 300 of fibers 350 attached to the substrate400 via stitching 304 such that a concentration/density of the stitches304 varies along the length of the bundle 300. For instance, the lengthof the bundle 300 may correspond to one of the segments 302 extending inthe direction from the lateral side 18 of the substrate 400 to themedial side 20 of the substrate 400 and the concentration/density of thestitches 304 increases along the length of the bundle 300 from themedial side 20 to the medial side 18.

FIG. 9 shows the stitches 304 crossing over the bundle 300 of fibers 350and penetrating the substrate 400 at attachment locations 305-1, 305-2,305-3, 305-4, 305-5, 305-6, 305-7, 305-8, 305-9, 305-10, 305-11, 305-12,305-13, 305-14 with each successive attachment location disposed on anopposite side of the bundle 300 in an alternating repeating fashion. Insome implementations, the concentration/density of the stitches 304 isproportional to lengths L₁, L₂, L₃ separating adjacent attachmentlocations disposed on a same side of the substrate 400. In the sampleshown, the lengths separating adjacent attachment locations 305 disposedon a same side of the substrate 400 decreases along the length of thebundle 300 from medial side 20 to the lateral side 18. For instance, afirst length L₁ separating the adjacent attachment locations 305-2 and305-4 is associated with a first concentration/density of stitching 304proximate to the medial side 20 of the substrate 400, a second length L₂separating the adjacent attachment locations 305-6 and 305-8 isassociated with a second concentration/density of stitching 304 withininterior regions of the substrate 400, and a third length L₃ separatingadjacent segments 305-10 and 305-12 is associated with a thirdconcentration/density of stitching 304 proximate to the lateral side 18.Here, the second concentration/density of stitching 304 associated withthe second length L₂ is greater than the first concentration/density ofstitching 304 associated with the longer first length L₁ but less thanthe third concentration/density of stitching 304 associated with theshorter third length L₃. While the example shows the varyingconcentration/density of stitching 304 increasing in the direction fromthe medial side 20 of the substrate 400 to the lateral side 18 of thesubstrate 400, the concentration/density of stitching 304 may increasein the opposite direction from the lateral side 18 of the substrate 400to the medial side 20 of the substrate 400 without departing from thescope of the present disclosure. Moreover, the concentration/density ofstitching 304 may also fluctuate between increasing and decreasing anumber of times along any given length of the bundle 300 of fibers 350including having the greatest concentration/density at a middle portionof the substrate 400 between the lateral side 18 and the medial side 20.

FIG. 10 provides a top view a strand/bundle 300 a of fibers 350 that mayform a layer 1000 of the footwear plate 200. The pattern of the bundle300 a of fibers 350 is shown relative to a peripheral edge P of thefinished footwear plate 200. In some examples, the bundle 300 a offibers 350 is affixed/attached to a base layer that includes acorresponding substrate 400 to form a first layer 1000 on the substrate400. In other examples, the bundle 300 a is affixed/attached on top of abase layer that includes an underlying sheet (e.g., unidirectional tape)or a layer of stand/bundle of fibers all affixed/attached to a singlesubstrate 400 in a layered configuration. In some configurations, thebundle 300 a is formed from a corresponding continuous strand of fibers350. In other configurations, however, the bundle 300 a is formed fromtwo or more strands of fibers 350. The bundle 300 a may range in sizefrom about 1,000 fibers per bundle to about 48,000 fibers per bundle. Insome examples, the bundle 300 a includes 12,000 fibers per bundle. Thebundle 300 a may be formed from the same or different fiber types as thebundle 300 of FIGS. 1-9. For instance, the bundle 300 a may include atleast one of carbon fibers, glass fibers, boron fibers, and/or syntheticpolymer fibers. Synthetic polymer fibers may include high tenacitysynthetic polymer fibers such as aramid fibers. The fibers 350 may becomingled with a thermoset polymer material and/or a thermoplasticpolymer material to assist with affixing the bundle 300 a to thesubstrate 400 and/or any other layers/sheets of fibers lying underneathor over top of the bundle 300 a to form the plate 200 (or otherarticle).

The substrate 400 defines a length extending along a longitudinal axis Lfrom a first end 201 to a second end 202 and a width extending between afirst side 18 (e.g., lateral side) and a second side 20 (e.g., medialside). When the stitched article is associated with a footwear plate200, the first end 201 corresponds to a toe end of the plate 200 and thesecond end 202 corresponds to a heel end of the plate 200. In theexample shown, a series of stitches 304 formed from a thread attach thestrand portion formed from the bundle 300 a of fibers 300 to thesubstrate 400. The stitches 304 may cross over the toe 300 a andpenetrate the substrate 400 at attachment locations that are spacedapart from the strand/toe 300 a as described above with reference toFIGS. 6-9. The stitches 304 may also penetrate the toe 300 a of fibers350 at one or more locations. In some examples, the substrate 400 is atextile including a first polymeric composition that includes one ormore first polymers and the thread associated with the stitching 304includes a second polymeric composition that includes one or more secondpolymers. In this example, at least one of the one or more firstpolymers is the same as at least one of the one or more second polymers.Optionally, a material (e.g., second polymeric material) forming thethread of stitching 304 may have a higher melting point than thematerial (e.g., first polymeric material) forming the substrate 400 sothat the stitching 304 holds the toe 300 a in place when the substrate400 begins to melt during a thermoforming process. In some examples, thestitching 304, or at least a portion thereof, is formed from resin. Insome examples, a melting temperature of the second polymeric compositionof the thread is at least 15-degrees Celsius (15° C.) higher than amelting temperature of the first polymeric composition of the substrate.

FIG. 10 shows the strand portion formed from the toe 300 a of fibers 350including looped portions 315 for connecting adjacent segments/coursesof the bundle 300 a. Some of the looped portions 315 extending outsidethe peripheral edge P may be removed by cutting along the peripheraledge P to remove the presence of pinch points that may occur whenapplying pressure for consolidating the fibers 350 to form the footwearplate 200. The looped portions 315 further define distal ends for theadjacent segments/courses of the bundle 300 a that terminate atrespective locations on the substrate 400 that are spaced apart from theperipheral edge P at the first end 201 to define a flex zone 450 of thesubstrate 400 at the distal ends. The flex zone 450 includes a greaterflexibility than other regions of the substrate 400 and, thus, isconfigured to provide a greater flexibility to the finished footwearplate 200 at a region where a wearer's foot naturally bends/flexesduring walking/running or other movements. The flex zone 450 may includea flexibility at least 5-percent (5%) greater than the flexibility ofthe other regions. In other examples, the flexibility of the flex zone450 is at least 10-percent (10%) greater than the flexibility of theother regions. Here, the concentration of fibers 350 is reduced byremoving the presence of fibers 350 at the flex zone 450 to accommodateanatomical features as well as to enhance performance of the footwear 10for its intended use. In the example shown, the distal ends in the flexzone 450 cooperate to define a transition line 1010 that extends fromthe medial side 20 to the lateral side 18 of the substrate 400. Whilethe transition line 1010 of FIG. 10 is arcuate, the distal ends of thebundle 300 a may be modified to form a transition line that is straight.The substrate 400 is exposed between the transition line 1010 and theperipheral edge P at the first end 201 of the substrate 400.

In some implementations, the toe 300 a includes a first length 310 and asecond length 312 each extending in a direction between the first side18 and the second side 20 (i.e., the toe 300 a is disposed at a non-zeroangle (excluding 180 degrees) relative to the longitudinal axis L of thesubstrate 400 such that the direction of the lengths 310, 312 isconvergent with the longitudinal axis L). In other configurations, thedirection may extend parallel to the longitudinal axis L withoutdeparting from the scope of the present disclosure.

In the example shown, the first length 310 and the second length 320 areassociated with a same length of the toe 300 a, with the bundleincluding a plurality of lengths/segments each extending parallel to oneanother between the heel region 16 and the forefoot region 12. Theconcentration of stitches 304 may be different along at least one ofthese plurality of lengths/segments than the other of the plurality oflengths/segments. Along at least one of the plurality oflengths/segments, the first length 310 is disposed closer to the firstend 201 of the substrate 400 than the second end 202 of the substrate400. For example, the first length 310 may be disposed within the flexzone 450 of the substrate 400 and the second length 310 may be disposedoutside of the flex zone 450. The stitches 304 in the flex zone 450 ofthe substrate 400 may include a first concentration along the firstlength 310 of the bundle 300 a and the stitches 304 outside the flexzone may include a second concentration along the second length 310 ofthe bundle 300 a. As the flex zone 450 of the substrate 400 is at thefirst length 310, the stitches 304 include a higher concentration alongthe first length 310 than the second length 312 to increaseinter-laminar fracture toughness at the flex zone 450 after the finishedplate 200 (or other article) is formed. Detailed views along respectiveportions of the first and second lengths 310, 312 of the bundle 300 aeach show the stitching 304 following the zigzagging pattern across thebundle 300 a and penetrating the substrate 400 at correspondingattachment locations 305. Optionally, the stitching 304 or a portionthereof may include “tacks” configured to attach portions of the bundle300 a to the substrate 400 or simply configured as embroidery toincrease inter-laminar fracture toughness in selected regions.

In some implementations, the first concentration is at least 10-percent(10%) greater than the second concentration. In some examples, the firstconcentration is 10-percent (10%) to 50-percent (50%) greater than thesecond concentration. The first concentration may be 20-percent (20%) to40-percent (40%) greater than the second concentration.

FIG. 11 provides a top view a strand/bundle 300 b of fibers 350 that mayform a layer 1100 of the footwear plate 200. The pattern of the bundle300 a of fibers 350 is shown relative to a peripheral edge P of thefinished footwear plate 200. In some examples, the bundle 300 b offibers 350 is affixed/attached to a base layer that includes acorresponding substrate 400 to form a first layer 1100 on the substrate400. In other examples, the bundle 300 b is affixed/attached on top of abase layer that includes an underlying sheet (e.g., unidirectional tape)or a layer of stand/bundle of fibers all affixed/attached to a singlesubstrate 400 in a layered configuration. As with the bundle 300 a offibers 350 of FIG. 10, the bundle 300 b of fibers 350 may be formed fromone continuous strand of fibers 350 or from two or more strands offibers 350, may range in size from about 1,000 fibers per bundle toabout 48,000 fibers per bundle, and may include at least one of carbonfibers, glass fibers, boron fibers, and/or synthetic polymer fibers.Synthetic polymer fibers may include high tenacity synthetic polymerfibers such as aramid fibers. Additionally, the fibers 350 may becomingled with a thermoset polymer material and/or a thermoplasticpolymer material to assist with affixing the bundle 300 b to thesubstrate 400 and/or any other layers/sheets of fibers lying underneathor over top of the bundle 300 b to form the plate 200 (or otherarticle).

Implementations include a series of stitches 304 formed from a thread toattach the bundle 300 b of fibers 300 to the substrate 400 by crossingover the bundle 300 b and penetrating the substrate 400 at attachmentlocations spaced apart from the strand/bundle 300 b and/or penetratingthe strand/bundle 300 b. In some examples, the substrate 400 is atextile including a first polymeric composition that includes one ormore first polymers and the thread associated with the stitching 304includes a second polymeric composition that includes one or more secondpolymers. In this example, at least one of the one or more firstpolymers is the same as at least one of the one or more second polymers.Optionally, a material (e.g., second polymeric material) forming thethread of stitching 304 may have a higher melting point than thematerial (e.g., first polymeric material) forming the substrate 400 sothat the stitching 304 holds the bundle 300 b in place when thesubstrate 400 begins to melt during a thermoforming process. In someexamples, the stitching 304, or at least a portion thereof, is formedfrom resin. In some examples, a melting temperature of the secondpolymeric composition of the thread is at least 15-degrees Celsius (15°C.) higher than a melting temperature of the first polymeric compositionof the substrate.

FIG. 11 shows the strand portion formed from the bundle 300 b includes aplurality of lengths (i.e., segments) 320 having longitudinal axes thatextend in a direction between the forefoot region 12 (e.g., firstregion) of the substrate 400 and the heel region 16 (e.g., secondregion) of the substrate 400. Looped portions 325 may connect adjacentlengths 320. Some of the looped portions 325 extending outside theperipheral edge P may be removed by cutting along the peripheral edge Pto remove the presence of pinch points that may occur when applyingpressure for consolidating the fibers 350 to form the footwear plate 200(or other article). Moreover, the substrate 400 includes a flex zone 460having a greater flexibility than other regions of the substrate 400.More specifically, the plurality of lengths 320 of the bundle 300 bpositioned on the substrate 400 include a first substantially straightportion 321 within the midfoot and heel region 14, 16 and an arcuateportion 322 within the forefoot region 12 that defines the flex zone460. Thus, the arcuate portions 322 of adjacent lengths 320 of thebundle 300 b are aligned to define the flex zone 460 with a straighttransition line 1110 extending across the width of the substrate 400between the lateral side 18 (e.g., first side) of the substrate 400 andthe medial side 20 (e.g., second side) of the substrate 400. Here, thearcuate portion 322 provides curvature to the path of the bundle 300 bof fibers 350 to thereby change directions in the load path of the plate200 to accommodate anatomical features as well as to enhance performanceof the footwear 10 for its intended use. Each length 320 of the bundle300 b may further include a second substantially straight portion 323within the forefoot region 12 that extends between the arcuate portion322 (flex zone 460) and the first end (e.g., toe end) 201 of thesubstrate 400.

The flex zone 460 includes a greater flexibility than other regions ofthe substrate 400 and, thus, is configured to provide a greaterflexibility to the finished footwear plate 200 at a region where awearer's foot naturally bends/flexes during walking/running or othermovements. The flex zone 460 may include a flexibility at least5-percent (5%) greater than the flexibility of the other regions. Inother examples, the flexibility of the flex zone 460 is at least10-percent (10%) greater than the flexibility of the other regions.

As with the stitches 304 attaching the bundle 300 a of FIG. 10, theconcentration of stitches 304 may be different along at least one of theplurality of lengths 320 of the bundle 300 b than the other of theplurality of lengths 320 of the bundle 300 b. The stitches 304 in theflex zone 460 of the substrate 400 may include a first concentrationalong the arcuate portion 322 of the bundle 300 b and the stitches 304outside the flex zone may include a second concentration along thesubstantially straight portions 321, 323 of the bundle 300 b. In theexample shown, the stitches 304 along each length 320 include a higherconcentration within the flex zone 460 than within other regions toincrease the inter-laminar fracture toughness at the flex zone 460 afterthe finished plate 200 (or other article) is formed. For instance, thedensity/concentration of the stitching 304 attaching the arcuateportions 322 of the bundle 300 b to the substrate 400 is greater thanthe density/concentration of the stitching 304 attaching the first andsecond substantially straight portions 321, 323 of the bundle 300 b tothe substrate 400. As with the stitches 304 attaching the bundle 300 aof FIG. 10, the stitching 304 along a portion of any of the lengths 320and/or arcuate portions 322 of the bundle 300 b may follow thezigzagging pattern across the bundle 300 b and penetrating the substrate400 at corresponding attachment locations 305. Optionally, the stitching304 or a portion thereof may include “tacks” configured to attachportions of the bundle 300 b to the substrate 400 or simply configuredas embroidery to increase inter-laminar fracture toughness in selectedregions.

In some implementations, the first concentration is at least 10-percent(10%) greater than the second concentration. In some examples, the firstconcentration is 10-percent (10%) to 50-percent (50%) greater than thesecond concentration. The first concentration may be 20-percent (20%) to40-percent (40%) greater than the second concentration.

FIG. 12 provides a top view the strand/bundle 300 c of fibers 350 thatmay form a layer 1200 of the footwear plate 200. The strand/bundle 300 cof fibers 350 is substantially identical to the strand/bundle 300 b offibers 350 of FIG. 11. In view of the substantial similarity instructure and function of the components associated with thestrand/bundle 300 c of the layer 1200 with respect to the strand/bundle300 b of the layer 1100, like reference numerals are used hereinafterand in the drawings to identify like components while like referencenumerals containing letter extensions are used to identify thosecomponents that have been modified.

As with the strand/bundle 300 b of fibers 350 forming the layer 1100 ofFIG. 11, the strand formed by the bundle 300 c of fibers 350 includes aplurality of lengths (i.e., segments) 330 having longitudinal axes thatextend in a direction between the forefoot region 12 (e.g., firstregion) of the substrate 400 and the heel region 16 (e.g., secondregion) of the substrate 400. The lengths 330 of the bundle 300 cdeposited on the substrate 400 include a first substantially straightportion 331 within the midfoot and heel region 14, 16 and an arcuateportion 332 within the forefoot region 12 that defines a flex zone 470that is larger than the flex zone 460 defined by the arcuate portions322 of the bundle 300 b of FIG. 11. Thus, the arcuate portions 332 ofadjacent lengths 330 of the bundle 300 c are aligned to define the flexzone 470 with the straight transition line 1110 extending across thewidth of the substrate 400 between the lateral side 18 (e.g., firstside) of the substrate 400 and the medial side 20 (e.g., second side) ofthe substrate 400. Here, the arcuate portion 332 provides curvature tothe path of the bundle 300 c of fibers 350 to thereby change directionsin the load path of the plate 200 to accommodate anatomical features aswell as to enhance performance of the footwear 10 for its intended use.Each length 330 of the bundle 300 c may further include a secondsubstantially straight portion 333 within the forefoot region 12 thatextends between the arcuate portion 332 (flex zone 470) and the firstend (e.g., toe end) 201 of the substrate 400.

As with the stitches 304 attaching the bundle 300 b of FIG. 11, theconcentration of stitches 304 may be different along at least one of theplurality of lengths 330 of the bundle 300 c than the other of theplurality of lengths 330 of the bundle 300 c. The stitches 304 in theflex zone 470 of the substrate 400 may include a first concentrationalong the arcuate portion 332 of the bundle 300 c and the stitches 304outside the flex zone may include a second concentration along thesubstantially straight portions 331, 333 of the bundle 300 b. In theexample shown, the stitches 304 along each length 330 include a higherconcentration within the flex zone 470 than within other regions toincrease the inter-laminar fracture toughness at the flex zone 470 afterthe finished plate 200 (or other article) is formed. For instance, thedensity/concentration of the stitching 304 attaching the arcuateportions 332 of the bundle 300 c to the substrate 400 is greater thanthe density/concentration of the stitching 304 attaching the first andsecond substantially straight portions 331, 333 of the bundle 300 c tothe substrate 400. As with the stitches 304 attaching the bundle 300 aof FIG. 10 and the bundle 300 b of FIG. 11, the stitching 304 along aportion of any of the lengths 330 and/or arcuate portions 332 of thebundle 300 c may follow the zigzagging pattern across the bundle 300 cand penetrating the substrate 400 at corresponding attachment locations305. Optionally, the stitching 304 or a portion thereof may include“tacks” configured to attach portions of the bundle 300 c to thesubstrate 400 or simply configured as embroidery to increaseinter-laminar fracture toughness in selected regions.

In some implementations, the first concentration is at least 10-percent(10%) greater than the second concentration. In some examples, the firstconcentration is 10-percent (10%) to 50-percent (50%) greater than thesecond concentration. The first concentration may be 20-percent (20%) to40-percent (40%) greater than the second concentration.

Referring to FIG. 13, the layer 1100 formed by the corresponding bundle300 b of fibers 350 may be incorporated into a series of stacked layers500 a-500 b of fibers 502 to increase flexibility in one or morelocalized regions and tune stiffness properties imparted by the finishedfootwear plate 200. Either or both of the layers 1000, 1200 of FIGS. 10and 12 could be incorporated into the series of stacked layers 500 a-500b of fibers 502 instead of, or in lieu of, the layer 1100 formed by thecorresponding bundle 300 b of fibers 350. In the example shown, thestacked layers 500 a-500 b are formed from individual strands 502 offibers, whereby each strand 502 refers to a plurality of fibers, amonofilament, a yarn, or a polymer pre-impregnated bundles. Forinstance, the strand 902 may include a plurality of carbon fibers and aplurality of resin fibers that, when activated, solidify and hold thecarbon fibers in a desired shape and position relative to one another.As used herein, the term “bundle” refers to a bundle (i.e., plurality offilaments (e.g., fibers 350) that may be twisted or untwisted and eachbundle may be designated a size associated with a number of fibers thecorresponding bundle contains. For instance, a single strand 502 mayrange in size from about 1,000 fibers per bundle to about 48,000 fibersper bundle. Each strand 502 may affix to a corresponding substrate 400,or all of the strands 502 may affix to a same substrate 400representative of a base layer for the footwear plate 200. In otherexamples, the layers 500 a-500 b are formed from prepreg fiber sheetsthat may be unidirectional tape or multi-axial fabric having fibers 502impregnated with resin. Alternatively, some of the layers 500 a-500 bmay be a unidirectional tape while others of the layers 500 a-500 b maybe a multi-axial fabric. Whether the layers 500 a-500 b correspond tolayers formed by corresponding strands 502 or correspond to sheets ofunidirectional tape or multi-axial fabric having the fibers 502, thefibers 502 include at least one of carbon fibers, glass fibers, boronfibers, and/or synthetic polymer fibers. Synthetic polymer fibers mayinclude high tenacity synthetic polymer fibers such as aramid fibers.Fibers such as carbon fibers, aramid fibers, and boron fibers mayprovide a high Young's modulus while glass fibers (e.g., fiberglass) andmedium tenacity polymer fibers (e.g., nylon or polyester fibers) providea medium modulus. The fiberglass fibers may include E6 318 fibersmanufactured by Jushi™. Carbon fibers may include Teryfyl TC35 fibers,Hyosun H2550 fibers or Tenax-E HTS 40 fibers.

In some implementations, the layers 500 a-500 b include fibers 502formed at different angles relative to one another such that alongitudinal axis of the fibers 502 (unidirectional tape, multi-axialfabric, strand) is positioned at an angle (Φ) relative to a longitudinalaxis (L) of each layer 500 a-500 b. In one configuration, the fibers 502of the layer 500 a are positioned at the angle (Φ) equal to 60 degrees(60°) relative to the longitudinal axis (L) and the fibers 502 of thelayer 500 b are positioned at the angle (Φ) equal to 0 degrees (0°)relative to the longitudinal axis (L). Accordingly, when the layers 500a-500 b are stacked on one another, the longitudinal axes of the fibers502 associated with the layers 500 a are positioned at different anglesrelative to the longitudinal axis (L) of the plate 200 while thelongitudinal axes of the fibers 502 associated with the layers 500 b arepositioned parallel to the longitudinal axis (L) of the plate 200. Thelayer 500 a and/or the layer 500 b could be positioned at differentangles relative to the longitudinal axis (L) in other configurations.

FIG. 13 shows a stacked configuration that includes a total of five (5)layers with a bottom layer 500 a including fibers 502 positioned at 60°relative to the longitudinal axis (L), the next layer 500 b includingfibers 502 positioned at 0° relative to the longitudinal axis (L), asingle layer 1100 of the bundle 300 b of fibers 350, the next layer 500b including fibers 502 positioned at 0° relative to the longitudinalaxis (L), and the top and final layer 500 a including fibers 502positioned at 60° relative to the longitudinal axis (L). In the exampleshown, the bottom layer 500 a is attached to the substrate 400 and theremaining layers 500 a, 500 b, 1100 also attach to the substrate 400over top the bottom layer 500 a. In other examples, at least two of thelayers 500 a-500 b, 1100 attach to a corresponding substrate 400.Stitching 304 is used to attach layers 500 a-500 b, 1100 to thesubstrate 400. The middle layer 1100 of the bundle 300 b of fibers 350provides a localized region of increased flexibility in the forefootregion 12 due to the flex zone 460 formed by the arcuate portions 322 ofthe bundle 300 b, while the stitching 304 attaching the bundle 300 b offibers 350 to the substrate 400 includes a concentration/density that ishigher in the flex zone 460 than in other regions to increase theinter-laminar fracture toughness of the plate 200 in the localizedregion of increased flexibility.

Referring to FIG. 14, in some implementations, one or more of the layers1100 formed by the corresponding bundle 300 b of fibers 350 may beincorporated into a series of stacked layers 600 a-600 b of fibers 602to increase flexibility in one or more localized regions and tunestiffness properties imparted by the finished footwear plate 200. Eitheror both of the layers 1000, 1200 of FIGS. 10 and 12 could beincorporated into the series of stacked layers 600 a-600 b of fibers 602instead of, or in lieu of, the layer 1100 formed by the correspondingbundle 300 b of fibers 350. As with the stacked layers 500 a-500 b ofFIG. 13, the stacked layers 600 a-600 b are formed from individualstrands 602 of fibers, whereby each strand 602 refers to a plurality offibers, a monofilament, a yarn, or a polymer pre-impregnated bundles.For instance, the strand 602 may include a plurality of carbon fibersand a plurality of resin fibers that, when activated, solidify and holdthe carbon fibers in a desired shape and position relative to oneanother. As used herein, the term “bundle” refers to a bundle (i.e.,plurality of filaments (e.g., fibers 350) that may be twisted oruntwisted and each bundle may be designated a size associated with anumber of fibers the corresponding bundle contains. For instance, asingle strand 602 may range in size from about 1,000 fibers per bundleto about 48,000 fibers per bundle. Each strand 602 may affix to acorresponding substrate 400, or all of the strands 602 may affix to asame substrate 400 representative of a base layer for the footwear plate200. In other examples, the layers 600 a-600 b are formed from prepregfiber sheets that may be unidirectional tape or multi-axial fabrichaving fibers 602 impregnated with resin. Alternatively, some of thelayers 600 a-600 b may be a unidirectional tape while others of thelayers 600 a-600 b may be a multi-axial fabric. Whether the layers 600a-600 b correspond to layers formed by corresponding strands 602 orcorrespond to sheets of unidirectional tape or multi-axial fabric havingthe fibers 602, the fibers 602 include at least one of carbon fibers,glass fibers, boron fibers, and/or synthetic polymer fibers. Syntheticpolymer fibers may include high tenacity synthetic polymer fibers suchas aramid fibers. Fibers such as carbon fibers, aramid fibers, and boronfibers may provide a high Young's modulus while glass fibers (e.g.,fiberglass) and medium tenacity polymer fibers (e.g., polyester or nylonfibers) provide a medium modulus. The fiberglass fibers may include E6318 fibers manufactured by Jushi™. Carbon fibers may include TeryfylTC35 fibers, Hyosun H2550 fibers or Tenax-E HTS 40 fibers.

In some implementations, the layers 600 a-600 b include fibers 602formed at different angles relative to one another such that alongitudinal axis of the fibers 602 (unidirectional tape, multi-axialfabric, strand) is positioned at an angle (Φ) relative to a longitudinalaxis (L) of each layer 600 a-600 b. In one configuration, the fibers 602of the layer 600 a are positioned at the angle (Φ) equal to 60 degrees(60°) relative to the longitudinal axis (L) and the fibers 602 of thelayer 600 b are positioned at the angle (Φ) equal to 0 degrees (0°)relative to the longitudinal axis (L). Accordingly, when the layers 600a-600 b are stacked on one another, the longitudinal axes of the fibers602 associated with the layers 600 a are positioned at different anglesrelative to the longitudinal axis (L) of the plate 200 while thelongitudinal axes of the fibers 602 associated with the layers 600 b arepositioned parallel to the longitudinal axis (L) of the plate 200. Thelayer 600 a and/or the layer 600 b could be positioned at differentangles relative to the longitudinal axis (L) in other configurations.

While the stacked configuration of FIG. 13 includes a total of five (5)layers, FIG. 14 shows a stacked configuration that includes a total offour (4) layers with a bottom layer 600 a including fibers 602positioned at 60° relative to the longitudinal axis (L), the next layer600 b including fibers 602 positioned at 0° relative to the longitudinalaxis (L), a single layer 1100 of the bundle 300 b of fibers 350, and thetop and final layer 600 a including fibers 602 positioned at 60°relative to the longitudinal axis (L). In the example shown, the bottomlayer 600 a is attached to the substrate 400 and the remaining layers600 a, 600 b, 1100 also attach to the substrate 400 over top the bottomlayer 600 a. In other examples, at least two of the layers 600 a-600 b,1100 attach to a corresponding substrate 400. Stitching 304 is used toattach layers 600 a-600 b, 1100 to the substrate 400. The middle layer1100 of the bundle 300 b of fibers 350 provides a localized region ofincreased flexibility in the forefoot region 12 due to the flex zone 460formed by the arcuate portions 322 of the bundle 300 b, while thestitching 304 attaching the bundle 300 b of fibers 350 to the substrate400 includes a concentration/density that is higher in the flex zone 460than in other regions to increase the inter-laminar fracture toughnessof the plate 200 in the localized region of increased flexibility.

Referring to FIG. 15, in some implementations, one or more of the layers1100 formed by the corresponding bundle 300 b of fibers 350 may beincorporated into a series of stacked layers 700 a of fibers 702 toincrease flexibility in one or more localized regions and tune stiffnessproperties imparted by the finished footwear plate 200. Either or bothof the layers 1000, 1200 of FIGS. 10 and 12 could be incorporated intothe series of stacked layers 700 a of fibers 702 instead of, or in lieuof, the layers 1100 formed by the corresponding bundle 300 b of fibers350. As with the stacked layers 500 a-500 b, 600 a-600 b of FIGS. 13 and14, the stacked layers 700 a are formed from individual strands 702 offibers, whereby each strand 702 refers to a plurality of fibers, amonofilament, a yarn, or a polymer pre-impregnated bundles. Forinstance, the strand 702 may include a plurality of carbon fibers and aplurality of resin fibers that, when activated, solidify and hold thecarbon fibers in a desired shape and position relative to one another.As used herein, the term “bundle” refers to a bundle (i.e., plurality offilaments (e.g., fibers 350) that may be twisted or untwisted and eachbundle may be designated a size associated with a number of fibers thecorresponding bundle contains. For instance, a single strand 702 mayrange in size from about 1,000 fibers per bundle to about 48,000 fibersper bundle. Each strand 702 may affix to a corresponding substrate 400,or all of the strands 702 may affix to a same substrate 400representative of a base layer for the footwear plate 200. In otherexamples, the layers 700 a are formed from prepreg fiber sheets that maybe unidirectional tape or multi-axial fabric having fibers 702impregnated with resin. Alternatively, some of the layers 700 a may be aunidirectional tape while others of the layers 700 a may be amulti-axial fabric. Whether the layers 700 a correspond to layers formedby corresponding strands 702 or correspond to sheets of unidirectionaltape or multi-axial fabric having the fibers 702, the fibers 702 includeat least one of carbon fibers, glass fibers, boron fibers, and/orsynthetic polymer fibers. Synthetic polymer fibers may include hightenacity synthetic polymer fibers such as aramid fibers. Fibers such ascarbon fibers, aramid fibers, and boron fibers may provide a highYoung's modulus while glass fibers (e.g., fiberglass) and mediumtenacity polymer fibers (e.g., polyester or nylon fibers) provide amedium modulus. The fiberglass fibers may include E6 318 fibersmanufactured by Jushi™. Carbon fibers may include Teryfyl TC35 fibers,Hyosun H2550 fibers or Tenax-E HTS 40 fibers.

In some implementations, the layers 700 a include fibers 702 formed atdifferent angles relative to one another such that a longitudinal axisof the fibers 702 (unidirectional tape, multi-axial fabric, strand) ispositioned at an angle (Φ) relative to a longitudinal axis (L) of eachlayer 700 a. In one configuration, the fibers 702 of the layers 700 aare positioned at the angle (Φ) equal to 60 degrees (60°) relative tothe longitudinal axis (L). Accordingly, when the layers 700 a arestacked on one another, the longitudinal axes of the fibers 702associated with the layers 700 a are positioned at different anglesrelative to the longitudinal axis (L) of the plate 200. The layer 600 acould be positioned at other angles than 60° relative to thelongitudinal axis (L) in other configurations.

FIG. 15 shows a stacked configuration that includes a total of four (4)layers with a bottom layer 700 a including fibers 702 positioned at 60°relative to the longitudinal axis (L), two (2) layers 1100 of the bundle300 b of fibers 350, and the top and final layer 700 a including fibers702 positioned at 60° relative to the longitudinal axis (L). In theexample shown, the bottom layer 700 a is attached to the substrate 400and the remaining layers 700 a, 1100 also attach to the substrate 400over top the bottom layer 700 a. In other examples, at least two of thelayers 700 a, 1100 attach to a corresponding substrate 400. Stitching304 is used to attach layers 700 a, 1100 to the substrate 400. The twomiddle layers 1100 of the bundle 300 b of fibers 350 provide localizedregions of increased flexibility in the forefoot region 12 due to theflex zones 460 formed by the arcuate portions 322 of the bundle 300 b,while the stitching 304 attaching each bundle 300 b of fibers 350 to thesubstrate 400 includes a concentration/density that is higher in theflex zones 460 than in other regions to increase the inter-laminarfracture toughness of the plate 200 in the localized region of increasedflexibility.

While the examples of FIGS. 13-15 are directed toward stacking layers offibers 702 upon one or more substrates 400 to form a footwear plate,other examples can include stacking layers of fibers upon one or moresubstrates 400 of different shapes to form other stitched articles thatinclude increased flexibility in one or more localized regions. Forexample, such other articles formed to have increased flexibility in oneor more localized regions can include a concentration/density ofstitching 304 that is higher in the localized region(s) to increase theinter-laminar fracture toughness of the finished article in thelocalized region(s) of increased flexibility.

FIGS. 13-15 depict that a first strand portion formed from a firstbundle of fibers may be attached to the substrate in at least first andsecond regions (e.g., heel and forefoot) via a series of stitches formedwith a second thread, and at least a second strand portion formed from asecond bundle of fibers may be attached to the substrate in at least thefirst and second regions via a series of stitches formed with a secondthread. The first bundle of fibers may include carbon fibers and thesecond bundle of fibers may include glass fibers. In some examples, aconcentration of the first bundle of fibers in the first region is atleast 5-percent (5 percent) greater than a concentration of the firstbundle of fibers in the second region. Additionally or alternatively, aconcentration of the second bundle of fibers in the second region is atleast 5-percent (5 percent) greater than a concentration of the secondbundle of fibers in the first region.

With particular reference to FIGS. 16 and 17, formation of a footwearplate 200 is described in conjunction with a mold 800. The mold 800includes a first mold half 802 and a second mold half 804. The moldhalves 802, 804 include a mold cavity 806 having the shape of thefootwear plate 200, to allow the mold 800 to impart the desired shape ofthe particular plate 200 to either the stacked layers 500 a-500 b ofFIG. 13 incorporating one or more of the layers 1000, 1100, 1200 ofFIGS. 10-12 formed by the corresponding first bundle 300 a, 300 b, 300 cof fibers 350, the stacked layers 600 a-600 b of FIG. 14 incorporatingone or more of the layers 1000, 1100, 1200 of FIGS. 10-12 formed by thecorresponding first bundle 300 a, 300 b, 300 c of fibers 350, or thestacked layers 700 a of FIG. 15 incorporating one or more of the layers1000, 1100, 1200 of FIGS. 10-12 formed by the corresponding first bundle300 a, 300 b, 300 c of fibers 350.

In some examples, the bundle 300 a, 300 b, 300 c attached to thecorresponding substrate 400 via the stitching 304 are consolidated via aresin, such as a liquid resin material applied to the bundle 300 a, 300b, 300 c, the substrate 400, and the stitching 304. The liquid resincould include a liquid epoxy. The liquid resin may be formed bycombining first and second reactive compositions to form the liquidresin. Application of the resin material could flow through the bundle300 a, 300 b, 300 c, the substrate 400, and the stitching 304 and thencure when subjected to heat and pressure by the mold 800. As discussedabove, the stitching 304 may be formed from a thread that may cross overthe bundle 300 a, 300 b, 300 c and/or penetrate the bundle 300 a, 300 b,300 c or other layers of fibers underneath to secure the bundle 300 a,300 b, 300 c to the substrate. For instance, the thread may be formedfrom a material having a higher melting point than that of the substrate400 so that the stitching 304 can hold the bundle 300 a, 300 b, 300 c inplace when the substrate 400 begins to melt during the thermoformingprocess. The thread may be formed from resin and/or formed from the sameor different material as the substrate. The substrate 400 may be formedfrom a textile including a first polymeric composition having one ormore first polymers and the thread may be formed from a second polymericcomposition including one or more second polymers, whereby at least oneof the one or more first polymers are the same as at least one of theone or more second polymers. The textile forming the substrate 400 maybe a non-woven textile. In some examples, a melting temperature of thesecond polymeric composition of the thread is at least 15-degreesCelsius (15° C.) higher than a melting temperature of the firstpolymeric composition of the substrate.

After forming the stacked sheets/layers 500 a-500 b, 600 a-600 b, 700 a,the sheets/layers 500 a-500 b, 600 a-600 b, 700 a are inserted betweenthe mold halves 802, 804 within the mold cavity 806. At this point, themold 800 is closed by moving the mold halves 802, 804 toward one anotheror by moving one of the mold halves 802, 804 toward the other mold half802, 804. Once closed, the mold 800 applies heat and pressure to thestacked sheets/layers 500 a-500 b, 600 a-600 b, 700 a disposed withinthe mold cavity 806 to activate the resin associated with the stackedsheets/layers 500 a-500 b, 600 a-600 b, 700 a. The heat and pressureapplied to the stacked sheets/layers 500 a-500 b, 600 a-600 b, 700 acauses the particular shape of the mold cavity 806 to be applied to thestacked sheets/layers 500 a-500 b, 600 a-600 b, 700 a and, once cured,the resin associated with the stacked sheets/layers 500 a-500 b, 600a-600 b, 700 a cause the stacked sheets/layers 500 a-500 b, 600 a-600 b,700 a to harden and retain the desired shape. In some examples, when theresin composition includes the liquid epoxy resin composition, theliquid epoxy resin composition cures prior to removing the compositearticle from the mold. Moreover, the incorporated layer(s) 1000, 1100,1200 formed by the corresponding bundles 300 a, 300 b, 300 c of fibers350 may include thermoplastic yarns and/or stitching 304 formed fromthermoplastic or thermoset material to assist with attaching to thestacked layers 500 a-500 b, 600 a-600 b, 700 a to retain the desiredshape.

In some implementations, the resin composition is a thermoplastic resincomposition contained within at least one of the substrate, the strandportion 300, 300 b, 300 c and the thread of the stitching 304. Thethermoplastic resin may consolidate the substrate, the strand portion,and the thread of the stitching 304 by flowing and infiltrating thefibers 350 of the strand portion. The thermoplastic resin compositionmay be allowed to re-solidify prior to removing the composition articlefrom the mold.

It should be noted that while the sheets/layers 500 a-500 b, 600 a-600b, 700 a are described as including a resin material, the sheets/layers500 a-500 b, 600 a-600 b, 700 a could additionally be supplied withresin that is infused within the mold 800. The infused resin could be inaddition to the impregnated resin of the sheets/layers 500 a-500 b, 600a-600 b, 700 a or, alternatively, could be used in place of theimpregnated resin. The infused resin may include a liquid epoxy,thermoplastic or thermoset material.

The forgoing processes may be used to form footwear plates andcushioning elements that may be used to manufacture custom-madefootwear. For instance, various measurements of the foot may be recordedto determine suitable dimensions of the footwear plate and thecushioning member(s) incorporated into the article of footwear.Additionally, data associated with the gate of the foot may be obtainedto determine if the foot is indicative of toe striking or heel striking.The foot measurements and obtained data may be used to determine optimalangles and radii of curvature of the footwear plate, as well as thethickness of the one or more cushioning members positioned above, below,or encapsulating the footwear plate. Moreover, the length and width ofthe footwear plate may be determined based on the collected data andfoot measurements. In some examples, the foot measurements and collecteddata are used to select the footwear plate and/or cushioning member(s)from a plurality of pre-fabricated footwear plates and/or cushioningmember(s) of various sizes and dimensions that closely match the foot ofthe wearer.

Custom footwear plates may further allow for tailoring of the stiffnessof the plate for a particular wearer of the footwear. For instance, thetendon stiffness and calf muscle strength of an athlete may be measuredto determine a suitable stiffness of the plate for use by the athlete.Here, the stiffness of the footwear plate can vary with the strength ofthe athlete or for the size/condition of the athlete's tendons.Additionally or alternatively, the stiffness of the plate may betailored based on biomechanics and running mechanics of a particularathlete, such as how the angles of the athlete's joints change duringrunning movements. In some examples, force and motion measurements ofthe athlete are obtained before manufacturing a custom plate for theathlete. In other examples, plates are manufactured in particular rangesor increments of stiffness to provide semi-custom footwear such thatindividual athletes may select a suitable stiffness.

The following Clauses provide an exemplary configuration for a method offorming a plate for an article of footwear described above.

Clause 1: A stitched article comprising: a substrate having a firstregion and a second region; and a first strand portion formed from afirst bundle of fibers, wherein the first bundle of fibers is attachedto the substrate in the first region and in the second region via aseries of stitches formed with a first thread, the first bundle offibers form a first layer on the substrate, and the article has a firstconcentration of the stitches in the first region along a first lengthof the first strand portion and a second concentration of the stitchesdifferent than the first concentration in the second region along asecond length of the first strand portion.

Clause 2: The stitched article of Clause 1, wherein the stitches crossover the first strand portion and penetrate the substrate at firstattachment locations that are spaced apart from the first strandportion, and cross over the second strand portion and penetrate thesubstrate at second attachment locations that are spaced apart from thesecond strand portion.

Clause 3: The stitched article of Clause 1, wherein the stitchespenetrate the first strand portion, or the second strand portion, orboth.

Clause 4: The stitched article of any of the preceding Clauses, whereinthe first length extends in a direction between a medial side of thesubstrate and a lateral side of the substrate.

Clause 5: The stitched article of Clause 4, wherein the second lengthextends in a direction between the medial side of the substrate and thelateral side of the substrate.

Clause 6: The stitched article of any of the preceding Clauses, whereinthe first concentration is greater than the second concentration.

Clause 7: The stitched article of Clause 6, wherein the firstconcentration is at least 10 percent greater than the secondconcentration.

Clause 8: The stitched article of Clause 7, wherein the firstconcentration is 10 percent to 50 percent greater than the secondconcentration.

Clause 9: The stitched article of Clause 8, wherein the firstconcentration is 20 percent to 40 percent greater than the secondconcentration.

Clause 10: The stitched article of any of the preceding Clauses, whereina first average distance between stitches in the first region is greaterthan a second average distance between stitches in the second region.

Clause 11: The stitched article of Clause 10, wherein the first averagedistance between stitches is at least 10 percent greater than the secondaverage distance between stitches.

Clause 12: The stitched article of Clause 11, wherein the first averagedistance between stitches is 10 percent to 50 percent greater than thesecond average distance between stitches.

Clause 13: The stitched article of Clause 12, wherein the first averagedistance between stitches is 20 percent to 40 percent greater than thesecond average distance between stitches.

Clause 14: The stitched article of any of Clauses 1-5 or 10-13, whereinthe second concentration is greater than the first concentration.

Clause 15: The stitched article of Clause 14, wherein the secondconcentration is at least 10 percent greater than the firstconcentration.

Clause 16: The stitched article of Clause 15, wherein the secondconcentration is 10 percent to 50 percent greater than the firstconcentration.

Clause 17: The stitched article of Clause 16, wherein the secondconcentration is 20 percent to 40 percent greater than the firstconcentration.

Clause 18: The stitched article of any of Clauses 1-9 or 14-17, whereina second average distance between stitches in the first region isgreater than a first average distance between stitches in the secondregion.

Clause 19: The stitched article of Clause 18, wherein the second averagedistance between stitches is at least 10 percent greater than the firstaverage distance between stitches.

Clause 20: The stitched article of Clause 19, wherein the second averagedistance between stitches is 10 percent to 50 percent greater than thefirst average distance between stitches.

Clause 21: The stitched article of Clause 20, wherein the second averagedistance between stitches is 20 percent to 40 percent greater than thefirst average distance between stitches.

Clause 22: The stitched article of any of the preceding Clauses, whereinthe substrate is a textile including a first polymeric compositioncomprising one or more first polymers.

Clause 23: The stitched article of any of the preceding Clauses, whereinthe thread includes a second polymeric composition comprising one ormore second polymers.

Clause 24: The stitched article of Clause 23, wherein both the firstpolymeric composition of the textile and the second polymericcomposition of the thread are thermoplastic compositions.

Clause 25: The stitched article of Clause 23 or 24, wherein both the oneor more first polymers of first polymeric composition of the textile andthe one or more second polymers of the second polymeric composition ofthe thread include a polyurethane, a polyester, a polyether, apolyamide, or a polyolefin.

Clause 26: The stitched article of Clause 22, wherein the textile is anon-woven textile.

Clause 27: The stitched article of any of the preceding Clauses, whereinthe bundle of fibers includes at least one of carbon fibers, boronfibers, glass fibers, and synthetic polymer fibers.

Clause 28: The stitched article of Clause 27, wherein the syntheticpolymer fibers comprise aramid fibers.

Clause 29: The stitched article of any of the preceding Clauses, whereinthe stitched article comprises a second strand portion formed from asecond bundle of fibers, and the second strand portion is attached tothe substrate in the first region and in the second region via a seriesof stitches formed with a second thread.

Clause 30: The stitched article of any preceding Clause, wherein thefirst bundle of fibers comprises carbon fibers.

Clause 31: The stitched article of Clause 29 or 30, wherein the secondbundle of fibers comprises glass fibers.

Clause 32: The stitched article of any of Clauses 29 to 31, wherein aconcentration of the first bundle of fibers in the first region is atleast 5 weight percent greater than a concentration of the first bundleof fibers in the second region.

Clause 33: The stitched article of any of Clauses 29 to 32, wherein aconcentration of the second bundle of fibers in the second region is atleast 5 weight percent greater than a concentration of the second bundleof fibers in the first region.

Clause 34: The stitched article of any of Clauses 23-33, wherein amelting temperature of the second polymeric composition of the thread isat least 20 degrees Celsius higher than a melting temperature of thefirst polymeric composition of the substrate.

Clause 35: The stitched article of any of the preceding Clauses, whereinthe series of stitches crosses over the first strand portion.

Clause 36: The stitched article of any of the preceding Clauses, whereinthe second region defines a flex zone having a greater flexibility thanthe first region.

Clause 37: The stitched article of Clause 36, wherein the flexibility ofthe second region is at least 5 percent greater than the flexibility ofthe first region.

Clause 38: The stitched article of Clause 37, wherein the flexibility ofthe second region is at least 10 percent greater than the flexibility ofthe first region.

Clause 39: The stitched article of Clauses 22-31 or 33-38, wherein thesecond concentration is greater than the first concentration.

Clause 40: The stitched article of any of the preceding Clauses, whereinthe stitched article is a component of an article of footwear, anarticle of apparel, or an article of sporting equipment.

Clause 41: The stitched article of Clause 40, wherein the stitchedarticle is a component of an article of footwear.

Clause 42: The stitched article of Clause 41, wherein the component ofan article of footwear is a component of a plate of an article offootwear.

Clause 43: A stitched article comprising: a substrate having a firstside and a second side, and a strand portion formed from a bundle offibers; wherein the strand portion is attached to the substrate via aseries of stitches formed with a thread, the strand portion forms afirst layer on the substrate, the strand portion includes a first lengthextending in a direction between the first side and the second side anda second length extending in a direction between the first side and thesecond side, and the stitches have a different concentration along thefirst length than the second length.

Clause 44: The stitched article of Clause 43, wherein the stitches crossover the strand portion and penetrate the substrate at first attachmentlocations that are spaced apart from the strand portion.

Clause 45: The stitched article of Clause 43, wherein the stitchespenetrate the strand portion.

Clause 46: The stitched article of any of the preceding Clauses, whereinthe substrate includes a first end and a second end, the first length islocated closer to the first end than the second length, and the firstlength has a greater concentration of the stitches than the secondlength.

Clause 47: The stitched article of Clause 46, wherein the substrateincludes a flex zone at the first length, and the flex zone has agreater flexibility than other regions of the substrate.

Clause 48: The stitched article of any of the preceding Clauses, whereinthe substrate is a textile including a first polymeric compositioncomprising one or more first polymers and the thread includes a secondpolymeric composition comprising one or more second polymers, wherein atleast one of the one or more first polymers is the same as at least oneof the one or more second polymers.

Clause 49: The stitched article of any of the preceding Clauses, whereinthe bundle of fibers includes at least one of carbon fibers, boronfibers, glass fibers, and synthetic polymer fibers.

Clause 50: The stitched article of Clause 48 or 49, wherein both thefirst polymeric composition of the textile and the second polymericcomposition of the thread are thermoplastic compositions.

Clause 51: The stitched article of Clause 48 or 50, wherein both the oneor more first polymers of first polymeric composition of the textile andthe one or more second polymers of the second polymeric composition ofthe thread include a polyurethane, a polyester, a polyether, apolyamide, or a polyolefin.

Clause 52: The stitched article of any of Clauses 48-51, wherein amelting temperature of the second polymeric composition of the thread isat least 20 degrees Celsius higher than a melting temperature of thefirst polymeric composition of the substrate.

Clause 53: The stitched article of any of the preceding Clauses, whereinthe series of stitches crosses over the strand portion.

Clause 54: A stitched article comprising a substrate having a first sideand a second side and a strand portion formed from a bundle of fibers,attached to the substrate via a series of stitches formed with a thread,forming a first layer on the substrate, and including a first lengthextending in a direction between the first side and the second side anda second length extending in a direction between the first side and thesecond side, a concentration of the stitches varying along at least oneof the first length and the second length between the first side and thesecond side.

Clause 55: The stitched article of Clause 54, wherein the stitches crossover the strand portion and penetrate the substrate at first attachmentlocations that are spaced apart from the strand portion.

Clause 56: The stitched article of Clause 54, wherein the stitchespenetrate the strand portion.

Clause 57: The stitched article of any of the preceding Clauses, whereinthe substrate includes a first end and a second end, the first lengthbeing located closer to the first end than the second length and havinga greater concentration of the stitches than the second length.

Clause 58: The stitched article of Clause 57, wherein the substrateincludes a flex zone at the first length, the flex zone having a greaterflexibility than other regions of the substrate.

Clause 59: The stitched article of any of the preceding Clauses, whereinthe substrate is a textile including a first polymeric compositioncomprising one or more first polymers and the thread includes a secondpolymeric composition comprising one or more second polymers, wherein atleast one of the one or more first polymers is the same as at least oneof the one or more second polymers.

Clause 60: The stitched article of any of the preceding Clauses, whereinthe bundle of fibers includes at least one of carbon fibers, aramidfibers, boron fibers, glass fibers, and polymer fibers.

Clause 61: The stitched article of any of the preceding Clauses, whereinthe thread is formed from resin.

Clause 62: The stitched article of any of the preceding Clauses, whereinthe thread is formed from the same material as the substrate.

Clause 63: The stitched article of any of the preceding Clauses, whereina material forming the thread has a higher melting point than thesubstrate.

Clause 64: The stitched article of any of the preceding Clauses, whereinthe series of stitches crosses over the strand portion.

Clause 65: A stitched article comprising a substrate having a firstregion and a second region and a strand portion formed from a bundle offibers, attached to the substrate via a series of stitches formed with athread, forming a first layer on the substrate, and including aplurality of lengths having longitudinal axes that extend in a directionbetween the first region and the second region and distal ends thatterminate at respective locations on the substrate that are spaced apartfrom an edge of the substrate to define a flex zone of the substrate atthe distal ends, the flex zone having a greater flexibility than otherregions of the substrate.

Clause 66: The stitched article of Clause 65, wherein the distal endscooperate to form a transition line that extends across a width of thesubstrate between a first side of the substrate and a second side of thesubstrate.

Clause 67: The stitched article of Clause 66, wherein the transitionline is arcuate.

Clause 68: The stitched article of Clause 66, wherein the transitionline is straight.

Clause 69: The stitched article of any of Clauses 66-68, wherein thetransition line extends from the first side to the second side.

Clause 70: The stitched article of any of Clauses 66-69, wherein thesubstrate is exposed between the transition line and the edge.

Clause 71: The stitched article of Clause 65, wherein the substrate isexposed between the distal ends and the edge.

Clause 72: The stitched article of Clause 65, wherein the stitches crossover the strand portion and penetrate the substrate at first attachmentlocations that are spaced apart from the strand portion.

Clause 73: The stitched article of Clause 65, wherein the stitchespenetrate the strand portion.

Clause 74: The stitched article of any of the preceding Clauses, whereina concentration of the stitches is different along at least one of theplurality of lengths than the other of the plurality of lengths.

Clause 75: The stitched article of Clause 74, wherein a concentration ofthe stitches varies along a length of at least one of the lengths of theplurality of lengths.

Clause 76: The stitched article of Clause 65, wherein a concentration ofthe stitches varies along a length of at least one of the lengths of theplurality of lengths.

Clause 77: The stitched article of any of the preceding Clauses, whereinthe substrate is a textile including a first polymeric compositioncomprising one or more first polymers and the thread includes a secondpolymeric composition comprising one or more second polymers, wherein atleast one of the one or more first polymers is the same as at least oneof the one or more second polymers.

Clause 78: The stitched article of any of the preceding Clauses, whereinthe bundle of fibers includes at least one of carbon fibers, aramidfibers, boron fibers, glass fibers, and polymer fibers.

Clause 79: The stitched article of any of the preceding Clauses, whereinthe thread is formed from resin.

Clause 80: The stitched article of any of the preceding Clauses, whereinthe thread is formed from the same material as the substrate.

Clause 81: The stitched article of any of the preceding Clauses, whereina material forming the thread has a higher melting point than thesubstrate.

Clause 82: The stitched article of any of the preceding Clauses, whereinthe series of stitches crosses over the strand portion.

Clause 83: A stitched article comprising a substrate having a firstregion and a second region and a strand portion formed from a bundle offibers, attached to the substrate via a series of stitches formed with athread, forming a first layer on the substrate, and including a flexzone having a greater flexibility than other regions of the substrate,the stitches having a greater concentration along a length of the strandportion within the flex zone than in the other regions of the substrate.

Clause 84: The stitched article of Clause 83, wherein the flex zonedefines a transition line that extends across a width of the substratebetween a first side of the substrate and a second side of thesubstrate.

Clause 85: The stitched article of Clause 84, wherein the transitionline is arcuate.

Clause 86: The stitched article of Clause 84, wherein the transitionline is straight.

Clause 87: The stitched article of any of Clauses 84-86, wherein thetransition line extends from the first side to the second side.

Clause 88: The stitched article of any of Clauses 84-87, wherein thesubstrate is exposed between the transition line and an edge of thesubstrate.

Clause 89: The stitched article of Clause 83, wherein the stitches crossover the strand portion and penetrate the substrate at first attachmentlocations that are spaced apart from the strand portion.

Clause 90: The stitched article of Clause 83, wherein the stitchespenetrate the strand portion.

Clause 91: The stitched article of any of the preceding Clauses, whereinthe substrate is a textile including a first polymeric compositioncomprising one or more first polymers and the thread includes a secondpolymeric composition comprising one or more second polymers, wherein atleast one of the one or more first polymers is the same as at least oneof the one or more second polymers.

Clause 92: The stitched article of any of the preceding Clauses, whereinthe bundle of fibers includes at least one of carbon fibers, boronfibers, glass fibers, and synthetic polymer fibers.

Clause 93: The stitched article of any of the preceding Clauses, whereinthe thread is formed from resin.

Clause 94: The stitched article of any of the preceding Clauses, whereinthe thread is formed from the same material as the substrate.

Clause 95: The stitched article of any of the preceding Clauses, whereina material forming the thread has a higher melting point than thesubstrate.

Clause 96: The stitched article of any of the preceding Clauses, whereinthe series of stitches crosses over the strand portion.

Clause 97: A method of forming a stitched article, the method comprisingpositioning a substrate, depositing a strand portion formed from abundle of fibers on the substrate, and attaching the strand portion tothe substrate via a series of stitches formed with a thread such that afirst region of the stitched article has a first concentration ofstitches and a second region of the stitched article has a secondconcentration of stitches, wherein the first concentration of stitchesis at least 10 percent greater than the second concentration ofstitches.

Clause 98: The method of Clause 97, wherein the stitched article is astitched article according to any of Clauses 1 to 96.

Clause 99: A method of forming a composite article, the methodcomprising positioning a stitched article in a mold, the stitchedarticle including strand portions of bundles of fibers stitched to asubstrate with a thread; while the stitched article is positioned in themold, consolidating the substrate, the strand portion, and the stitchesvia a resin composition to form a composite article, and removing thecomposite article from the mold, wherein the composite article includesa first region and a second region, the second region including a flexzone having a greater flexibility than the first region.

Clause 100: The method of Clause 99, wherein the method furthercomprises forming the stitched article prior to the positioning thestitched article in the mold.

Clause 101: The method of Clause 100, wherein the forming the stitchedarticle comprises depositing a strand portion formed from a bundle offibers on a substrate, and attaching the strand portion via a series ofstitches formed with a thread to the substrate in a first region havinga first concentration of stitches and in a second region having a secondregion of stitches greater than the first concentration of stitches.

Clause 102: The method of Clause 101, wherein the stitched article is astitched article according to any of Clauses 1 to 96.

Clause 103: The method of any of the preceding Clauses, whereinconsolidating the substrate, the strand portion, and the stitchingincludes applying the resin composition to the substrate, the strandportion, and the stitching while the stitched article is positioned inthe mold.

Clause 104: The method of Clause 99, wherein applying the resincomposition includes combining first and second reactive compositions toform a liquid resin composition, and applying the liquid resincomposition to the stitched article.

Clause 105: The method of Clause 104, wherein the liquid resincomposition is a liquid epoxy resin composition.

Clause 106: The method of any of Clauses 103 to 105, further comprisingcuring the resin composition prior to removing the composite articlefrom the mold.

Clause 107: The method of any of Clauses 103 to 106, wherein the resincomposition is a thermoplastic resin composition contained within atleast one of the substrate, the strand portion, and the thread of thestitched article, and consolidating the substrate, the strand portion,and the thread includes causing the resin composition to flow andinfiltrate the fibers of the strand portion, followed by allowing theresin composition to re-solidify prior to removing the composite articlefrom the mold.

Clause 108: The method of any of the preceding Clauses, wherein themethod further comprises trimming a perimeter of the composite article.

Clause 109: The method of Clause 108, further comprising forming thesubstrate, the strand portion, and the stitching into a plate for anarticle of footwear.

Clause 110: The method of Clause 109, further comprising incorporatingthe plate into an article of footwear.

Clause 111: The method of Clause 99, wherein depositing the strandportion on the substrate includes positioning the strand portion in aplurality of lengths having longitudinal axes that extend in a directionbetween the first region and the second region, the plurality of lengthshaving distal ends that terminate at respective locations on thesubstrate that are spaced apart from an edge of the substrate to definethe flex zone.

Clause 112: The method of Clause 99, wherein depositing the strandportion on the substrate includes positioning the strand portion in aplurality of lengths having a first substantially straight portionwithin the first region and an arcuate portion within the second regionthat defines the flex zone.

Clause 113: The method of Clause 99, further comprising aligning arcuateportions of adjacent lengths to define the flex zone.

Clause 114: The method of any of the preceding Clauses, whereinattaching the strand portion via a series of stitches formed with athread includes causing the stitches to cross over the strand portionand penetrate the substrate at first attachment locations that arespaced apart from the strand portion.

Clause 115: The method of Clauses 99-108, wherein attaching the strandportion via a series of stitches formed with a thread includes causingthe stitches to penetrate the strand portion.

Clause 116: A method of manufacturing an article of footwear, apparel orsporting equipment, the method comprising positioning a compositearticle, the composite article comprising a stitched article havingstrand portions of bundles of fibers stitched to a substrate with athread, the wherein the fibers are consolidated by a resin composition,wherein the composite article is a component of an article of footwear,apparel or sporting equipment, and affixing the composite article and asecond component to each other, wherein the second component is a secondcomponent of an article of footwear, apparel or sporting equipment.

Clause 117: The method of Clause 116, wherein the composite article is acomponent of an article of footwear, and the second component is asecond component of an article of footwear.

Clause 118: The method of Clause 117, wherein the composite article is aplate for an article of footwear.

Clause 119: A composite article comprising: a stitched article accordingto any of Clauses 1 to 96 and a resin composition, wherein the resincomposition consolidates fibers of at least the first bundle of fibersof the strand portion.

Clause 120: The composite article of clause 119, wherein the resincomposition consolidates the fibers of at least the first bundle offibers of the strand portion, fibers and/or a yarn of the substrate, andthread of the stitched article.

Clause 121: The composite article of Clause 119 or 120, wherein theresin composition is a thermoset resin composition, and the thermosetresin composition optionally comprises an epoxy resin.

Clause 122: The composite article of any of Clauses 119-121, wherein theresin composition is a thermoplastic resin composition, and thethermoplastic resin composition optionally comprises a thermoplasticpolyurethane, a thermoplastic polyester, a thermoplastic polyether, athermoplastic polyamide, a thermoplastic polyolefin, or any combinationthereof.

Clause 123: The composite article of any of Clauses 119 to 122, whereinthe composite article is a plate for an article of footwear.

Clause 124: The plate for an article of footwear of Clause 123, whereinthe plate comprises a plurality of traction elements; and one or more ofthe plurality of traction elements optionally includes a tip configuredto be ground-contacting, and optionally wherein the tip is formed from adifferent polymeric material than the resin composition of the plate.

Clause 125: A method of forming a plate for an article of footwearincluding positioning a substrate, depositing a strand portion formedfrom a bundle of fibers on the substrate, and attaching the strandportion to the substrate via a series of stitches formed with a threadsuch that a first region of the stitched article has a firstconcentration of stitches and a second region of the stitched articlehas a second concentration of stitches, wherein the first concentrationof stitches is at least 10 percent greater than the second concentrationof stitches.

Clause 126: The method of Clause 125, wherein the method furthercomprises positioning the stitched article in a mold, disposing a liquidresin composition between and around a plurality of fibers of the bundleof fibers stitched to the substrate, solidifying the liquid resincomposition, consolidating the plurality of fibers with solid resincomposition and forming a composite plate for an article of footwear,and removing the composite plate from the mold.

Clause 127: The method of Clause 126, further comprising disposing atleast one traction element in the mold prior to disposing the liquidresin composition and attaching the traction element to the compositeplate prior to removing the composite plate from the mold.

Clause 128: The method of Clauses 125-127, further comprisingincorporating the plate into a sole structure of the article offootwear.

Clause 129: The method of Clauses 125-127, further comprisingincorporating the plate into the article of footwear.

Clause 130: A plate formed by the method of any of Clauses 125-127.

Clause 131: A sole structure formed by the method of any of Clauses125-127.

Clause 132: An article of footwear formed by the method of any ofClauses 125-127.

Clause 133: A method of forming a composite plate for an article offootwear including positioning a stitched article in a mold, thestitched article including strand portions of bundles of fibers stitchedto a substrate with a thread, wherein a first region of the stitchedarticle has a first concentration of stitches and a second region of thestitched article has a second concentration of stitches, wherein thefirst concentration of stitches is at least 10 percent greater than thesecond concentration of stitches, while the stitched article ispositioned in the mold, disposing a resin composition between and arounda plurality of fibers of the bundle of fibers stitched to the substrate,consolidating the plurality of fibers with the resin composition andforming a composite plate for an article of footwear including a firstregion and a second region, the second region including a flex zonehaving a greater flexibility than the first region, and removing thecomposite plate from the mold.

Clause 134: The method of Clause 133, wherein the method furthercomprises forming the stitched article prior to the positioning thestitched article in the mold.

Clause 135: The method of Clauses 133-134, further comprisingincorporating the plate into a sole structure of the article offootwear.

Clause 136: The method of Clauses 133-134, further comprisingincorporating the plate into the article of footwear.

Clause 137: A plate formed by the method of any of Clauses 133-134.

Clause 138: A sole structure formed by the method of any of Clauses133-134.

Clause 139: An article of footwear formed by the method of any ofClauses 133-134.

The foregoing description has been provided for purposes of illustrationand description. It is not intended to be exhaustive or to limit thedisclosure. Individual elements or features of a particularconfiguration are generally not limited to that particularconfiguration, but, where applicable, are interchangeable and can beused in a selected configuration, even if not specifically shown ordescribed. The same may also be varied in many ways. Such variations arenot to be regarded as a departure from the disclosure, and all suchmodifications are intended to be included within the scope of thedisclosure.

What is claimed is:
 1. A method for forming a plate for an article offootwear, the method comprising: forming a stitched article including:proving a substrate with a first region and a second region; andattaching a first strand portion formed from a first bundle of fibers tothe substrate in the first region and in the second region via a seriesof stitches formed with a first thread to form a first layer on thesubstrate, the stitched article having a first concentration of thestitches in the first region along a first length of the first strandportion and a second concentration of the stitches different than thefirst concentration in the second region along a second length of thefirst strand portion.
 2. The method of claim 1, further comprisingconsolidating at least one of (i) fibers of at least the first bundle offibers of the first strand portion, (ii) fibers and/or a yarn of thesubstrate, and (iii) the first thread of the stitched article with aresin composition.
 3. The method of claim 1, further comprising crossingthe stitches over the first strand portion and penetrating the substrateat first attachment locations that are spaced apart from the firststrand portion.
 4. The method of claim 1, further comprising extendingthe first length of the first strand portion in a direction between amedial side of the substrate and a lateral side of the substrate.
 5. Themethod of claim 4, further comprising extending the second length of thefirst strand portion in a direction between the medial side of thesubstrate and the lateral side of the substrate.
 6. The method of claim1, wherein the first concentration is greater than the secondconcentration.
 7. The method of claim 1, further comprising providing afirst average distance between stitches in the first region that isgreater than a second average distance between stitches in the secondregion.
 8. The method of claim 1, wherein attaching the first strandportion formed from the first bundle of fibers to the substrate includesattaching a first bundle of fibers including at least one of carbonfibers, boron fibers, glass fibers, and synthetic polymer fibers.
 9. Themethod of claim 1, wherein forming the stitched article includesattaching a second strand portion formed from a second bundle of fibersto the substrate in the first region and in the second region via aseries of stitches formed with a second thread.
 10. The method of claim9, wherein attaching the first strand portion formed from the firstbundle of fibers to the substrate includes attaching a first bundle offibers including carbon fiber, and attaching the second strand portionformed from the second bundle of fibers to the substrate includesattaching a second bundle of fibers including glass fibers.
 11. Themethod of claim 1, further comprising forming the substrate from atextile including a first polymeric composition comprising one or morefirst polymers, and forming the first thread includes forming the firstthread from a second polymeric composition comprising one or more secondpolymers.
 12. The method of claim 11, further comprising forming boththe first polymeric composition of the textile and the second polymericcomposition of the first thread from a thermoplastic composition. 13.The method of claim 11, further comprising forming both the one or morefirst polymers of the first polymeric composition of the textile and theone or more second polymers of the second polymeric composition of thefirst thread from a polyurethane, or to include a polyester, or toinclude a polyether, or to include a polyamide, or to include apolyolefin.
 14. The method of claim 11, further comprising providing thesecond polymeric composition of the first thread with a meltingtemperature of at least 20 degrees Celsius higher than a meltingtemperature of the first polymeric composition of the substrate.
 15. Themethod of claim 1, further comprising attaching a plurality of tractionelements to a side of the plate.
 16. A method of forming a plate for anarticle of footwear, the method comprising: positioning a substrate;depositing a strand portion formed from a bundle of fibers on thesubstrate; and attaching the strand portion to the substrate via aseries of stitches formed with a thread to form a stitched article, afirst region of the stitched article having a first concentration ofstitches and a second region of the stitched article having a secondconcentration of stitches, wherein the first concentration of stitchesis at least 10 percent greater than the second concentration ofstitches.
 17. The method of claim 16, wherein the method furthercomprises positioning the stitched article in a mold; disposing a liquidresin composition between and around a plurality of fibers of the bundleof fibers stitched to the substrate; solidifying the liquid resincomposition, consolidating the plurality of fibers with solid resincomposition and forming a composite plate for an article of footwear;and removing the composite plate from the mold.
 18. The method of claim17, further comprising disposing at least one traction element in themold prior to disposing the liquid resin composition; and attaching thetraction element to the composite plate prior to removing the compositeplate from the mold.
 19. A method of forming a composite plate for anarticle of footwear, the method comprising: positioning a stitchedarticle in a mold, the stitched article including strand portions ofbundles of fibers stitched to a substrate with a thread, wherein a firstregion of the stitched article has a first concentration of stitches anda second region of the stitched article has a second concentration ofstitches, wherein the first concentration of stitches is at least 10percent greater than the second concentration of stitches; while thestitched article is positioned in the mold, disposing a resincomposition between and around a plurality of fibers of the bundles offibers stitched to the substrate, consolidating the plurality of fiberswith the resin composition and forming a composite plate for an articleof footwear including a first region and a second region, the secondregion including a flex zone having a greater flexibility than the firstregion; and removing the composite plate from the mold.
 20. The methodof claim 19, wherein the method further comprises forming the stitchedarticle prior to the positioning the stitched article in the mold.